Body temperature control system

ABSTRACT

In an embodiment, a system is provided. The system includes a heat exchanger including a compressor and having a pump coupled to the heat exchanger. The system further includes a personal garment, the personal garment including an internal bladder with inflow and outflow fluid tubing. The fluid tubing is coupled to the heat exchanger.

CLAIM OF PRIORITY

This application claims priority to U.S. Provisional Application No. 60/178,066, filed May 14, 2009, which is hereby incorporated herein by reference. This application claims priority to U.S. Provisional Application No. 60/285,198, filed Dec. 10, 2009, which is hereby incorporated herein by reference.

BACKGROUND

Temperature control for human beings can be a very valuable benefit. While the human body self-regulates body temperature as much as possible, we tend to expose our bodies to situations where self-regulation becomes difficult or impossible. In such situations, performance of tasks becomes less efficient, judgment can be impaired, and other adverse effects manifest. Thus, it may be valuable to devise a system which can allow a person to avoid the worst effects of extreme temperatures by assisting in regulation of body temperature.

Regulation of temperature in the torso can provide much benefit to a person experiencing temperature extremes. One example of a situation that can cause temperature extremes is a race (automobile race) set in an extreme temperature environment. Past attempts to provide a system for controlling body temperature have focused on overheating and attempts to cool a driver. FIG. 1 illustrates such a system, available from F.A.S.T. of Arlington Heights, Ill.

In particular, FIG. 1 illustrates a cool shirt system. System 100 includes a shirt 110, cooling mechanism 120, connecting hose 130 and shirt tubing 140. Cooling mechanism 120 operates by using ice (solid water) to cool liquid water. Cooling mechanism 120 is connected to connecting hoses 130, which in turn are connected to shirt tubing 140. Water is pumped through connecting hoses 130 and shirt tubing 140 from cooling mechanism 120 using a pump in cooling mechanism 120 (not shown). The ice in cooling mechanism 120 cools the water, which then circulates to the cool shirt 110, removing heat from a user of the shirt 110. Also shown is a control 145 which allows a user to control how much water flows through the shirt 110, thus allowing some modulation of the cooling effect. Other, similar systems are available from Shafer Enterprises of Stockbridge, Ga., for example.

This system allows for basic cooling under hot conditions. However, it suffers from some potential drawbacks. For example, a supply of ice is required to provide cooling—if no ice is available the system does not function. Additionally, in situations where multiple drivers use the system, conservation of ice to allow for cooling of later racers can frustrate teammates. Moreover, the system allows relatively minimal temperature control, providing for cooling which can only be varied somewhat based on flow rates. Also, the use of ice means that the system is unlikely to be useful for warming a person in cold situations. Thus, it may be advantageous to provide a system which can provide more flexible temperature control.

Cooling garments in particular tend to rely on one of four techniques. One example is freezing—frozen substance packets are placed in pockets on the garment which continue to absorb heat from the body until the packet has completely thawed. Another example is wicking—variable-stitch fabric is used to create shirts which wick warm moisture away from the wearer's body where it can be more easily evaporated.

A third example is phase change—specialized materials are placed in pockets or under head-wear which resolve to a specific temperature. One such material resolves to 55 degrees. These materials continue to absorb heat around them at a specific rate to achieve an expected surface temperature (such as 55 degrees) until they are saturated and no longer offer a cooling surface to the wearer. Note that freezing represents a phase change as well, typically from solid to liquid. The fourth example technique is fluid based heat exchange. A cooling fluid, typically water, is passed over the wearer's body via a network of plastic tubes wherein the fluid absorbs heat from the wearer and transports it to some form of cooling system. Each of these techniques has advantages and disadvantages. However, particularly for techniques using a cooling fluid, providing improved opportunities to transfer heat from a wearer of a garment to the associated cooling fluid may be beneficial.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is illustrated by way of example in the accompanying drawings. The drawings should be understood as illustrative rather than limiting.

FIG. 1 illustrates an embodiment of a cool shirt system.

FIG. 2 illustrates an embodiment of a body temperature control system.

FIG. 3 illustrates an embodiment of a heat exchanger usable in a body temperature control system.

FIG. 4 (collectively FIGS. 4A, 4B and 4C) illustrates an embodiment of a thermal exchange block such as may be used in a heat exchanger.

FIG. 5 illustrates installation of an embodiment of a body temperature control system in a car.

FIG. 6 illustrates an embodiment of a process of assembly of a body temperature control system.

FIG. 7 illustrates an embodiment of a process of installation of a body temperature control system.

FIG. 8 illustrates an embodiment of a fluid transport loop of a body temperature control system.

FIG. 9 illustrates an embodiment of a process of operation of a body temperature control system.

FIG. 10 illustrates an embodiment of a controller which may be used in an embodiment of a body temperature control system installed in vehicle.

FIG. 11 illustrates another embodiment of a controller which may be used in an embodiment of a body temperature control system.

FIG. 12 illustrates another embodiment of a body temperature control system.

FIG. 13 illustrates yet another embodiment of a body temperature control system.

FIGS. 14 and 15 illustrate an embodiment of a heat exchanger.

FIG. 16 illustrates an embodiment of a fan.

FIG. 17 illustrates another embodiment of a heat exchange block, in assembled (FIG. 17A), exploded (FIGS. 17B, 17C), and back views (FIG. 17D).

FIG. 18 illustrates another embodiment of a heat exchange block, in an assembled view (FIG. 18A), and with component views (FIGS. 18B, 18C and 18D).

FIG. 19A illustrates another embodiment of a body temperature control system.

FIG. 19B illustrates yet another embodiment of a body temperature control system.

FIG. 19C illustrates an embodiment of a heat exchange block in block diagram form.

FIG. 19D illustrates a perspective view of an embodiment of a body temperature control system as it may be arranged physically.

FIG. 19E illustrates another perspective view of the embodiment of a body temperature control system of FIG. 19D.

FIG. 20 illustrates an embodiment of a shirt, in front (FIG. 20A) and back views (FIG. 20B).

FIG. 21 illustrates an embodiment of a bladder of the front of the shirt of FIG. 20.

FIG. 22 illustrates an embodiment of a bladder of the back of the shirt of FIG. 20.

FIG. 23 illustrates an exploded perspective view of the bladder of the back of the shirt of FIG. 20.

FIG. 24 illustrates an exploded perspective view of the bladder of the front of the shirt of FIG. 20.

FIG. 25 illustrates an exploded perspective view of a bladder such as the bladders of FIGS. 23 and 24.

FIG. 26 illustrates another embodiment of a garment in the form of a vest.

FIG. 27 illustrates a top view of the vest of FIG. 26 as laid flat.

FIG. 28 illustrates an exploded view of the vest of FIG. 26.

FIG. 29 illustrates yet another embodiment of a heat exchanger.

FIG. 30 illustrates an embodiment of a shirt that may be used with various system embodiments.

FIG. 31 illustrates in FIGS. 31A, 31B, 31C, 31D and 31E, construction of a bladder for use in the shirt of FIG. 30 and other garments.

FIG. 32 illustrates in FIGS. 32A, 32B and 32C, a combination of a shirt with a bladder in an embodiment.

FIG. 33 illustrates another embodiment of a bladder.

FIG. 34 illustrates another embodiment of a cooling system.

FIG. 35 illustrates another embodiment of a garment that may be used with a cooling system.

FIG. 36A illustrates a back view of an embodiment of a garment that may be used with a cooling system.

FIG. 36B illustrates a front view of an embodiment of a garment that may be used with a cooling system.

FIG. 36C illustrates a cross-sectional view along a line A-A of an embodiment of a garment that may be used with a cooling system.

FIG. 36D illustrates a cross-sectional view along a line B-B of an embodiment of a garment that may be used with a cooling system.

FIG. 37 illustrates in FIGS. 37A, 37B, 37C and 37D, an embodiment of a cooling block.

FIG. 38 illustrates in FIGS. 38A, 38B, 38C and 38D, an embodiment of an internal cooling block of a cooling block.

FIG. 39 illustrates in FIGS. 39A, 39B, 39C, 39D, 39E and 39F, an embodiment of an external cooling block of a cooling block.

FIG. 40 illustrates an embodiment of a body temperature control system.

FIG. 41 illustrates an embodiment of a control interface for a body temperature control system.

FIG. 42 illustrates another embodiment of a cooling device in perspective view.

FIG. 43A illustrates another view of the cooling device of FIG. 42 in perspective view with visibility of interior components.

FIG. 43B illustrates yet another view of the cooling device of FIG. 42 in perspective view with a top removed.

FIG. 43C illustrates another view of the cooling device of FIG. 42 in a top view with visibility of interior components.

FIG. 43D illustrates another view of the cooling device of FIG. 42 in a side view with visibility of interior components.

FIG. 44A illustrates a view of the heat exchanger of the cooling device of FIG. 42 in perspective view.

FIG. 44B illustrates a view of the heat exchanger of the cooling device of FIG. 42 in a top view.

FIG. 44C illustrates a view of the heat exchanger of the cooling device of FIG. 42 in a side view.

FIG. 45A illustrates another embodiment of a cooling system, using the cooling device of FIG. 42.

FIG. 45B illustrates the embodiment of a cooling system of FIG. 45A.

FIG. 46A illustrates yet another embodiment of a cooling device in a top view with an open lid.

FIG. 46B illustrates the cooling device of FIG. 46A in perspective view with a closed lid.

FIG. 46C illustrates the cooling device of FIG. 46A in perspective view with an open lid.

FIG. 46D illustrates the cooling device of FIG. 46A in a side view with an open lid.

FIG. 46E illustrates the cooling device of FIG. 46A in a perspective view with an open lid.

FIG. 46F illustrates another embodiment of a cooling device in a perspective view with a closed lid.

FIG. 46G illustrates the cooling device of FIG. 46A in a cutaway perspective view with an open lid.

FIG. 46H illustrates the cooling device of FIG. 46A in a top view with an open lid showing some hidden components in a schematic illustration.

FIG. 47A illustrates an embodiment of a cooling device such as the cooling device of FIG. 46A in a side view.

FIG. 47B illustrates the cooling device of FIG. 47A in a side view with flow illustrated.

FIG. 47C illustrates the cooling device of FIG. 47A in a cutaway perspective view.

FIG. 47D illustrates the cooling device of FIG. 47A in a perspective view.

FIG. 47E illustrates an embodiment of a cooling device such as the cooling device of FIG. 47A in a perspective view.

FIG. 47F illustrates the cooling device of FIG. 47E in a perspective view with hose connections illustrated.

FIG. 48 illustrates another embodiment of a cooling device such as the cooling devices of FIG. 46A or FIG. 46F.

FIG. 49 illustrates yet another embodiment of a cooling device such as the cooling devices of FIG. 46A or FIG. 46F.

The drawings should be understood as illustrative rather than limiting.

DETAILED DESCRIPTION

A system, method and apparatus is provided for a body temperature control system. In one embodiment, the body temperature control system uses a pump to move a fluid through two heat exchangers which either a) move heat from a user's body to the heat exchanger, thereby causing the user to feel cooler or b) move heat from the heat exchanger to the user's body, thereby causing the user to feel warmer. The specific embodiments described in this document represent example embodiments of the present invention, and are illustrative in nature rather than restrictive.

In an embodiment, a personal garment is provided. The personal garment includes an inner layer formed from a wicking material. The personal garment also includes an internal bladder having a first outer layer and a second outer layer sealed along a perimeter of the internal bladder. The internal bladder further has a middle layer interposed between the outer layer and the inner layer. The middle layer has voids therein defining a space in which fluid can circulate within the internal bladder. The internal bladder further has an inflow and an outflow tube interposed between the first outer layer and the second outer layer at the perimeter of the internal bladder. The personal garment also includes an outer layer formed from a wicking material. The outer layer is connected to the internal bladder. The outer layer and the inner layer seal the internal bladder away from surface contact with ambient atmosphere.

In another embodiment, a personal garment is provided. The personal garment includes an inner layer formed from a wicking material. The personal garment also includes an internal bladder having a first outer layer and a second outer layer sealed along a perimeter of the internal bladder. The internal bladder has a middle layer interposed between the outer layer and the inner layer. The middle layer has voids therein defining a space in which fluid can circulate within the internal bladder. The internal bladder further has an inflow and an outflow tube interposed between the first outer layer and the second outer layer at the perimeter of the internal bladder. The personal garment further includes an outer layer formed from a wicking material. The outer layer of the personal garment is connected to the inner layer of the inner layer. The outer layer and the inner layer define a pocket in which the internal bladder is enclosed, with the pocket having an external opening aligned with the inflow tube and the outflow tube of the bladder. Note that while a wicking material has been described herein, other materials may be used for the garment.

In an embodiment, a system is provided. The system includes a heat exchanger including a thermoelectric cooler. The system also includes a pump coupled to the heat exchanger. The system further includes a personal garment. The personal garment includes fluid tubing. The fluid tubing is coupled to the heat exchanger.

The system may further include a reservoir coupled to the heat exchanger. The system may also include a controller coupled to the heat exchanger. The system may further include a power supply coupled to the controller. The controller may further be coupled to the pump.

In an embodiment, the heat exchanger includes a thermal exchange block having a top surface and a first thermoelectric cooler abutting the top surface of the thermal exchanger block. The heat exchanger further includes a first heat sink thermally coupled to the first thermoelectric cooler. The system may further include a first fan thermally coupled to the first heat sink. In another embodiment, the heat exchanger may be further characterized by the thermal exchange block further including a bottom surface and the heat exchanger further including a second thermoelectric cooler abutting the bottom surface of the thermal exchange block and a second heat sink thermally coupled to the second thermoelectric cooler. Likewise, the embodiment may further include a second fan thermally coupled to the second heat sink.

In some embodiments, the thermal exchange block includes an internal fluid channel having an inlet and an outlet. The thermal fluid channel is disposed adjacent to the first thermoelectric cooler. The inlet and the outlet are coupled to the pump and the fluid tubing of the personal garment.

In some embodiments, the system further includes a user interface coupled to the controller. In some embodiments, the controller alters operation of the heat exchanger responsive to signals from the user interface. In some embodiments, the system is mounted in an automobile and the power supply is a power supply of the automobile. In some embodiments, the system is portable. Moreover, in some embodiments, the power supply is a rechargeable power supply. Alternatively, in some embodiments, the power supply receives power from a utility power grid. Additionally, in some embodiments, the personal garment is a shirt, whereas in other embodiments the personal garment is a body suit.

In another embodiment, a system is provided. The system includes a heat exchanger including a thermal exchange block having a top surface and a bottom surface. The system further includes a first thermoelectric cooler abutting the top surface of the thermal exchanger block and a first heat sink thermally coupled to the first thermoelectric cooler. The system also includes a second thermoelectric cooler abutting the bottom surface of the thermal exchanger block and a second heat sink thermally coupled to the second thermoelectric cooler.

The system also includes a pump coupled to the heat exchanger in fluid communication therewith. The system further includes a controller coupled to the heat exchanger and the pump. The system also includes a personal fabric component including fluid tubing. The fluid tubing of the personal fabric component is coupled to the heat exchanger in fluid communication therewith.

In yet another embodiment, a system is provided. The system includes a heat exchanger including a thermal exchange block having a top surface. The heat exchanger further includes a first thermoelectric cooler abutting the top surface of the thermal exchanger block and a first heat sink thermally coupled to the first thermoelectric cooler. The system further includes a pump coupled to the heat exchanger. The system also includes a controller coupled to the heat exchanger. The system further includes a personal fabric component. The personal fabric component includes fluid tubing and the fluid tubing is coupled to the heat exchanger. In some embodiments, the personal fabric component is a shirt. In other embodiments, the personal fabric component is a blanket.

In still another embodiment, a method is provided. The method includes installing a gasket on a thermal exchange block. The thermal exchange block includes an internal fluid transport channel having an inlet and an outlet. The method further includes securely connecting a thermoelectric cooler to the thermal exchange block in contact with the gasket. The method also includes fastening a heat sink to the thermoelectric cooler in a position opposite the thermal exchange block. The method further includes connecting a first tube to the inlet of the fluid transport channel and connecting the first tube to a fluid tube of a personal garment. The method also includes connecting a second tube to the fluid tube of the personal garment and connecting the second tube to a pump. The method further includes connecting a third tube to the pump and connecting the third tube to the outlet of the fluid transport channel.

In another embodiment, a method is presented. The method includes flowing fluid through a fluid loop including a heat exchanger, a personal garment and a pump. The method also includes adjusting a temperature of the fluid at the heat exchanger through use of a thermoelectric cooler. The method further includes receiving control signals from a user interface at a controller. The method also includes controlling the heat exchanger through signals from the controller responsive to the signals from the user interface.

In another embodiment, a system is provided. The system includes a heat exchanger. The heat exchanger includes an internal thermal exchange block having a top surface and a bottom surface. A first thermoelectric cooler abuts the top surface of the internal thermal exchanger block. A second thermoelectric cooler abuts the bottom surface of the internal thermal exchanger block. The heat exchanger further includes a first external thermal exchange block having a top surface and a bottom surface. A third thermoelectric cooler and a fourth thermoelectric cooler abut the bottom surface of the first external thermal exchange block. A first heat spreader abuts the third thermoelectric cooler and the fourth thermoelectric cooler. The heat spreader also abuts the first thermoelectric cooler. The heat exchanger also includes a second external thermal exchange block having a top surface and a bottom surface. A fifth thermoelectric cooler and a sixth thermoelectric cooler abut the top surface of the second external thermal exchange block. A second heat spreader abuts the fifth thermoelectric cooler and the sixth thermoelectric cooler. The heat spreader also abuts the second thermoelectric cooler.

The system further includes a first pump coupled to the internal thermal exchange block in fluid communication. The system further includes a second pump coupled to the first and second external thermal exchange blocks in fluid communication. The system also includes a controller coupled to the heat exchanger and the first pump and the second pump. The system further includes a personal fabric component. The personal fabric component includes fluid passages. The fluid passages are coupled to the internal thermal exchange block in fluid communication. The system may further include a radiator coupled in fluid communication with the second pump and the first and second external thermal exchange blocks.

In some embodiments, the first thermoelectric cooler abuts an internal top surface of the internal thermal exchange block and the second thermoelectric cooler abuts an internal bottom surface of the internal thermal exchange block. The third thermoelectric cooler and the fourth thermoelectric cooler abut an internal bottom surface of the first external thermal exchange block. The fifth thermoelectric cooler and the sixth thermoelectric cooler abut an internal top surface of the second external thermal exchange block. The first external thermoelectric exchange block abuts the internal thermoelectric exchange block and the second external thermoelectric exchange block abuts the internal thermoelectric exchange block. In some embodiments, the first heat spreader abuts an internal surface of the first external thermal exchange block and the second heat spreader abuts an internal surface of the second external thermal exchange block.

In some embodiments, the internal thermal exchange block includes an internal passage in fluid communication with the first pump. The internal fluid passage is bounded on one side by the first thermoelectric cooler and on the other side by the second thermoelectric cooler. The first external thermal exchange block includes an internal passage in fluid communication with the second pump. The internal fluid passage of the first external thermal exchange block is bounded on one side by the third thermoelectric cooler and the fourth thermoelectric cooler and on the other side by an internal surface of the first external thermal exchange block. The second external thermal exchange block includes an internal passage in fluid communication with the second pump. The internal fluid passage of the second external thermal exchange block is bounded on one side by the fifth thermoelectric cooler and the sixth thermoelectric cooler and on the other side by an internal surface of the second external thermal exchange block.

In some embodiments, the personal garment includes an inner layer formed from a wicking material. The personal garment further includes an internal bladder having a first outer layer and a second outer layer sealed along a perimeter of the internal bladder. The internal bladder further has a middle layer interposed between the outer layer and the inner layer and having voids therein defining a space in which fluid can circulate within the internal bladder. The internal bladder further has an inflow and an outflow tube interposed between the first outer layer and the second outer layer at the perimeter of the internal bladder. The personal garment further has an outer layer formed from a wicking material. The outer layer is connected to the internal layer. The outer layer and the inner layer define a pocket in which the internal bladder is enclosed. The pocket has an external opening aligned with the inflow tube and the outflow tube of the bladder.

In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the invention. It will be apparent, however, to one skilled in the art that the invention can be practiced without these specific details. In other instances, structures and devices are shown in block diagram form in order to avoid obscuring the invention.

Reference in the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Features and aspects of various embodiments may be integrated into other embodiments, and embodiments illustrated in this document may be implemented without all of the features or aspects illustrated or described.

Embodiments may solve many of the problems identified above and provide a system and components that meet many, if not all, of the identified needs. Further, the system may present all of these components in a single unified platform, or as a set of separate components. In an embodiment, five major components are used. These components include a heat exchange garment, a heat exchanger, a pump, a reservoir, and a controller. In one embodiment, the system components are described as follows:

The heat exchange garment is an item to be worn by, or placed very near the user which allows the system fluid to pass near the user's skin. The heat exchange garment allows for thermal transference between the user and the system. It can be used in either heating or cooling modes and provides a sealed (non-vented) portion of the fluid transportation path.

The heat exchanger warms or cools the system fluid depending on the user's preference. The warming and cooling is done via Peltier (thermoelectric) technology. Excess heat is dissipated to the atmosphere through an outside face of a Peltier device and may involve an additional heat sink. The heat sink may see increased efficiency resulting from the use of exhaust fans drawing atmospheric air over the heat sink. The heat exchanger is a sealed (non-vented) portion of the fluid transport path as well. The operation of the heat exchanger (heating or cooling of the system fluid) is determined by the flow of current through the Peltier device(s) attached to a thermal exchange block. By reversing the current polarity, the Peltier device(s) switch thermal flow direction allowing for heating or cooling.

One of the following two conditions obtains in such a situation. Cooling mode—heat is pumped from the fluid as it passes through the thermal exchange block, thereby cooling the system fluid and heating the ‘outside’ of the Peltier device(s). The Peltier device(s) dissipate heat to the atmosphere via the heat-sink and fan arrangement. Heating mode—heat is pumped into the fluid as it passes through the thermal exchange block, thereby warming the system fluid. This cools the ‘outside’ of the Peltier device(s) which are warmed by the atmosphere via the heat-sink and fan arrangement, or can be warmed by an optional heater in some embodiments.

The pump moves the system fluid through the heat exchanger, heat exchange garment and the reservoir. The reservoir potentially serves three functions in the system, though its use is not necessarily required for the system to operate properly. First, the reservoir can be used to fill or empty the system of fluid. For example, in the case of connecting an un-filled heat exchange garment to the system, the reservoir may provide fluid to fill the garment. Second, the reservoir allows the venting of gas bubbles in the system fluid to the atmosphere. Third, the reservoir is a stabilizing element preventing immediate and drastic changes in system fluid temperatures.

The Controller is an electrical (or electromechanical) device which allows the user to set the desired level of relative heating or cooling, and adjusts the various electrical outputs to drive the other components (e.g. appropriate voltage delivery to the pump and heat exchange block). The controller is operated via controls located on the controller device or via a user control panel which is mounted in any desirable position (e.g. a vehicle dash board, user wrist, hospital bed control panel, tank turret control panel, or other application-dependent position). The controller receives power input from a power source (e.g. a vehicle alternator, battery, fuel cell, solar cell, generator or other AC or DC voltage source).

Reference to the embodiment of FIG. 2, which provides an embodiment of a body temperature control system, may further illustrate the system. As illustrated, system 200 of FIG. 2 includes a reservoir 220, pump 225, heat exchanger 230, and heat exchange garment 250 arranged in a fluid loop 210. Thermometers 235 and 245 are provided to monitor temperature of the fluid at entry and exit points of the heat exchanger 230. Each component of the loop 210 is coupled to the next component of the loop 210 using sealed tubing or other fluid carrying components. As illustrated, the reservoir 220 is vented, allowing for release of gas bubbles and similar pressure release.

Controller 260 is illustrated coupled to heat exchanger 230, providing control signals to heat exchanger 230. Controller 260 is also coupled to power source 270, and provides power to heat exchanger 230, user controls 280, and potentially to pump 225 (connection not shown). Alternately, pump 225 may be coupled directly to power source 270. User controls 280 provide a user interface for system 200, allowing user adjustment of the temperature effect delivered by the garment 250. Also, thermometers 235 and 245 may be coupled to controller 260 to provide data to controller 260 and allow for feedback control of heat exchanger 230 and/or pump 225, for example. Note that the fluid used may be water or may be a different fluid useful for transport of heat. If water is used, saline or a disinfectant of some form may be added to avoid organic contamination in the system.

Further reference to FIG. 3 and the illustrated embodiment of a heat exchanger may provide additional insight into the system. Heat exchanger 300 is shown as a symmetrical design in block diagram form. Thermal exchange block 340 is provided as a fluid transport block which may be heated or cooled to heat or cool the transported fluid. Peltier thermal transducer(s) 330 (a and b) are provided in contact with thermal exchange block 340 to either transfer heat into or out of the thermal exchange block 340, depending on the bias voltage of the transducer 330. Heat sink(s) 320 (a and b) are described as finned, but can take various forms, and provide a radiating or absorbing surface attached to the Peltier transducer(s) 330. Fan(s) 310 (a and b) are provided to increase air flow over heat sink(s) 320, potentially increasing heat exchange efficiency, and are coupled to or in communication with heat sink(s) 320.

Heat exchanger 300 may be built as a single-ended system or a double-ended system (as shown). The single-ended system may potentially be more compact, whereas the double-ended system shown may potentially be more efficient. The various components of heat exchanger 300 may be controlled separately, such as controlling electrical bias of the Peltier thermal transducers 330 with a first signal (or set of signals) and controlling operations of fans 310 with a second signal (or set of signals).

The heat exchanger 300 may be further understood with reference to an embodiment of a thermal exchange block as illustrated in FIG. 4. Note that FIG. 4A illustrates a top view, FIG. 4B illustrates a front view, and FIG. 4C illustrates a side view. The back view (not illustrated) is a solid block much like the side view. The bottom view (and bottom side or surface) may be implemented as an essentially identical form to that of the top side (with an open channel) for use in double-ended assemblies, or in the form of a solid surface without access to the channel for use in single-ended assemblies.

Thermal exchange block 400 includes the block 410, fluid transport channel 440, barbs 430, recess 420, and gaskets (not shown). Block 410 has embodied therein fluid channel 440, which allows for transport of fluid through block 410 along a surface or surfaces (e.g. a top surface and a bottom surface) which may be in contact with Peltier thermal transducers, for example. Alternatively, the fluid channel 440 may be open on one or both surfaces, allowing direct contact between the fluid of the fluid channel 440 and an associated Peltier device. Recesses 420 are provided on the surfaces where contact with the transducers is desired to allow for insertion of gaskets or O-rings, for example, to facilitate such contact. Barbs 430 are provided at an inlet and outlet of fluid channel 440, to allow for interface with the rest of a fluid transport system, such as through connection to a set of hoses, for example. Note that in some embodiments, the system may also be fabricated with a barrier between the channel 440 and components exterior to the block 410, either as a result of not opening the top and/or bottom surfaces, or as a result of attaching plates to cover the top and/or bottom surfaces.

The overall system (body temperature control system) may be installed in a car for racing purposes, for example. Such an installation is illustrated in FIG. 5. System 500 represents a system including a body temperature control system and a car frame. Other installations may also be useful, and various different configurations may be used.

As illustrated, frame 540 may be a cage installed in a race car, or may represent the available mounting surfaces in a car. Shirt 510 is provided and may be worn by a driver. It is coupled to the heat exchange module 520, which is mounted on frame 540, along with reservoir 530. Reservoir 530 is an optional part of the system, which is coupled in the illustration to heat exchange module 520. Not shown is a pump, which may be integrated with heat exchange module 520. Also shown is a controller 550. Controller 550 is mounted to frame 540. In the illustrated embodiment, controller 550 is mounted in a location convenient for a driver, and includes a user interface integrated therein. In other embodiments, the controller may be mounted elsewhere and coupled to a user interface mounted conveniently for a driver. Controller 550 is coupled to heat exchange module 520 and controls heat exchange module 520 at least partially responsive to commands from a driver. Controller 550 may also regulate operation of heat exchange module 520 to maintain safe operation (e.g. within preset temperature limits).

Assembly of the body temperature control system, in one embodiment, includes building the heat exchanger block, building the controller (and its sub-system control panel), completing the fluid transport path between the components and connecting the electrical wiring for the system. In other embodiments, components such as the heat exchanger block and controller can be provided in prepared form.

Building the heat exchanger may be accomplished by following the following process, for each side of the heat exchanger. Reference to FIG. 6 may further illustrate this process. Process 600 begins with milling, cutting, drilling, and tapping a metal block to form the fluid transport channels and inlet/outlet to form the thermal exchange block at module 610. In some embodiments, this block may be pre-made. Next, at module 620, install O-Rings to seal the thermal exchange block to a Peltier device. Following that, at module 630, install the Peltier device. Next, install Peltier device clamping plate(s) with a heat transference compound, or otherwise affix the Peltier device to the thermal exchange block at module 640. Note that this assumes contact between the Peltier devices and the fluid of the thermal exchange block. With no contact with the fluid, gaskets and the like may not be necessary. Thereafter, at module 650, install a heat sink and at module 660, install a cooling fan. The process has been described with respect to assembly of a single-ended heat exchanger, or a single side of a double-ended heat exchanger. One may also assemble both sides of a double-ended heat exchanger as illustrated in FIG. 6.

The controller can also be assembled from typical components. The controller may include a processor, for example, or may be made using analog electrical components or mechanical components, for example. To create an appropriate controller, one establishes input voltage based on a source voltage for the application (e.g. a 12V car battery). One then creates or integrates a voltage regulation circuit for the heat exchanger block output(s) including control signals for Peltier device(s) and exhaust fan(s). One also includes or creates a comparator circuit. The comparator circuit may accept user input via a control panel and compare to Peltier device(s) output (e.g. warmer or cooler and OFF setting). This may include feedback indication (LED's) for the user. Moreover, the output signals may also come from thermometers provided in the device, for example. One also installs connectors for the various device and control panel leads, thereby connecting or coupling to a user interface and to the heat exchanger (and pump if separate).

The fluid reservoir includes a vented vessel containing sufficient capacity of fluid to replenish the fluid transport system in the event that an ‘empty’ heat exchange garment is connected and used in one embodiment. The fluid reservoir is installed through use of input and output connections leading to the heat exchange garment and fluid transport pump in one embodiment. Similarly, the heat exchange garment is assembled using a suitable article of clothing or surface which will place the system fluid within proximity of the user's body or specific body part to be warmed or cooled. The fluid transport system is then connected, by connecting the various components of the fluid transport system in a loop. One order may be: Reservoir->Pump->Heat Exchanger->Heat Exchange Garment->Reservoir. Assembly of the system also includes connecting the control system. This includes using suitable wiring and connectors to make the following connections in one embodiment: 1) Power Source->Controller, 2) Controller->Control Panel(s), 3) Controller->Exhaust Fan(s), 4) Controller->Peltier Device(s) and 5) Controller->Pump(s). One may further understand such a process by reference to FIG. 7.

FIG. 7 illustrates an embodiment of a process for assembling a system such as the body temperature control systems of various embodiments. Process 700 initiates with provision of a heat exchange component such as a heat exchange or thermal exchange block and associated components at module 710. At module 720, the heat exchange component is mounted or installed in the area where it is to operate. At module 730, a controller is connected or coupled to the heat exchange component, such as through electrical wiring. At module 740, a fluid transport system is coupled to the heat exchange component. This may involve connecting tubing for such a system to the heat exchange component and to other fluid transport components such as a personal garment with fluid tubing and a reservoir, for example. At module 750, a user control interface is connected or coupled to the controller, such as through electrical wiring or radio coupling. At module 760, a power source is coupled to the controller, such as through wiring to a battery or alternator of a vehicle or plugging into an electrical outlet, for example.

FIG. 8 illustrates a completed fluid transport loop in such embodiments. Loop 800 provides for transport of fluid between a heat exchanger 820 and a heat exchange garment 830. Pump 810 assists transfer of the fluid. In some embodiments, the loop is completed with pump 810, exchanger 820 and garment 830. Other embodiments also include reservoir 840 in the loop 800.

Using the system may be understood with reference to FIG. 9. After the body temperature control system is assembled and installed, the user can then don the heat exchange garment and use the control panel to feel warmer or cooler. When the user selects a control position to make them cooler, the controller sends an appropriate voltage and polarity to the pump(s), exhaust fan(s), Peltier device(s), and control indicators(s) which cause the heat exchanger to make the system fluid cooler. As the fluid passes through the heat exchange garment(s), the wearer(s) feels cooler. Alternatively, when the user selects a control position to make them warmer, the controller sends an appropriate voltage and polarity to the pump(s), exhaust fan(s), Peltier device(s), and control indicators(s) which cause the heat exchanger to make the system fluid warmer. As the fluid passes through the heat exchange garment(s), the wearer(s) feel warmer.

Referring more specifically to FIG. 9, process 900 initiates at module 910 with initiation of fluid flow. At module 920, a user command is received. At module 930, a determination is made as to whether to cool or heat. If to cool, cooling settings are set or adjusted at module 940. If to heat, heating settings are adjusted at module 950. At module 960, a determination is made as to whether a shutdown command was received. If so, at module 970 the fluid flow and power is shut down, and if not, the process returns to module 920 to await a user command.

Further reference to embodiments of a controller which may be used with various embodiments of the systems may illustrate additional details. FIG. 10 illustrates an embodiment of a controller which may be used in an embodiment of a body temperature control system installed in vehicle. System 1000 provides a controller which may be mounted in a vehicle and deliver power based on an associated vehicle power source. Terminals 1005 provide for reception of power from a power supply, such as a car battery or alternator. As illustrated, a 13.8 V potential difference is expected for an embodiment. Other embodiments may be used with different forms of power, such as other DC power sources or AC power sources, for example.

Switch 1010 provides a power switch coupled to a power supply terminal 1005 in the form of a single pole, single throw switch in one embodiment. Such a switch may simply supply or cut-off power to the system. Switches 1015 and 1020 are coupled between a TEC array 1030 and the power terminals 1005. TEC array 1030 represents a set of thermoelectric coolers which are described above, such as the TEC devices 330 of FIG. 3. Switches 1015 and 1020 operate collectively to supply power to TEC array 1030 and to bias TEC array 1030 for either cooling or heating. Thus, a user may have access to controls coupled to switches 1010, 1015 and 1020 to control the system (or the user may have direct access to switches 1010, 1015 and 1020).

Power is also supplied to other components. For example, pump 1040 is coupled through controller 1000 to the power terminals 1005 to receive power. Similarly, fans 1050 are coupled through controller 1000 to receive power from terminals 1005. Such a design requires that the pump 1040 and fans 1050 be adapted to receive the power available at terminals 1005. However, voltage regulators and other components can be included as needed in some embodiments. Note that pump 1040 may correspond to pump 225 of FIG. 2, for example. Similarly, fans 1050 may correspond to fans 310 of FIG. 3, for example.

FIG. 11 illustrates another embodiment of a controller which may be used in an embodiment of a body temperature control system. Controller 1100 includes a user interface 1110, thermal regulation module 1120, pump control module 1130, fan or ventilation control 1140 and power interface 1150. User interface 1110 may be coupled to an external user interface component or may be part of a user interface presented to a user. Thermal regulation module 1120 may be a circuit or other module which supplies power to TEC components and/or regulates the TEC components and is coupled thereto. This may include receipt of input from thermometers as well as output of signals to a TEC component or a set or plurality of TEC components, for example. This may also include regulation of the TEC components to maintain temperatures within safety guidelines, for example.

Pump control module 1130 may supply power to and/or regulate operation of a pump or pumps coupled thereto. Fan control module 1140 may likewise supply power and/or regulate operation of a fan or fans coupled thereto. Power interface module 1150 may receive power from a power source such as a battery or alternator of a car, or other power source such as a DC or AC electrical source. Power interface 1150 may regulate such power or simply pass it to components such as thermal regulator 1120, pump controller 1130 and fan controller 1140, for example.

Note that the control systems can be enhanced to include features which may be useful in various environments. For example, a user interface may be included with varying types of user controls and signals (e.g. LEDs, LCD screen, etc.) Additionally, the power interface of a controller may have a low battery detection circuit or power fault detection circuit. Such a circuit can be used to switch to a backup power supply or to shutdown the system. Likewise, the controller can include detection circuitry which can detect such conditions as low fluid levels, out of bounds temperatures, faults in the system generally (e.g. a pump failure) and other conditions. Moreover, temperature regulation and user interface components can be used to allow sophisticated temperature settings, such as a set temperature or a gradient to a set point, for example. Likewise, the system (e.g. the controller) can detect such conditions as power startup or ignition in a vehicle, and shut off to allow for cranking of an engine for example.

Another embodiment of the system may involve a heat exchanger dedicated to cooling in hot environments. FIG. 12 illustrates another embodiment of a body temperature control system. System 1200 is designed to cool a driver in hot environments, and may be adapted to cooling in general in hot environments.

System 1200 includes a cooling garment 1210, heat exchange block 1290, pump 1225 and a reservoir 1230 in a cool loop. Also included is another pump 1255 and radiator 1270 in a hot loop with heat exchanger block 1290. The hot loop may also use a reservoir 1230, which is illustrated as a common reservoir 1230 in FIG. 12, but may be provided as two separate (hot and cold) reservoirs 1230 in some embodiments. Additionally, blower 1280 may be provided to bring the ambient air supply to radiator 1270. Heat exchange block 1290 includes a cold loop heat exchanger 1220, a TEC array 1240 and a hot loop heat exchanger 1250. Thus, TEC array 1240 may transfer heat from the cold loop (through heat exchanger 1220) to the hot loop (through heat exchanger 1250), cooling fluid supplied to the garment 1210, and using radiator 1270 to remove heat from the system. As illustrated, a single-ended system is provided, with TECs on one side of each heat exchanger. In an ambient environment of 115 (degrees) F., one may potentially achieve a drop of 60 (degrees) F. within the system. Driver controls 1260 provide an option for controlling TEC array 1240, decreasing or increasing the amount of cooling.

Other implementations may be provided in similar embodiments. FIG. 13 illustrates yet another embodiment of a body temperature control system. System 1300 is likewise designed to cool a driver in hot environments, and may be adapted to cooling in general in hot environments.

System 1300 includes a cooling garment 1310, heat exchange block 1390, pump 1325 and a reservoir 1330 in a cool loop. System 1300 also includes another pump 1335 and radiator 1370 in a hot loop with heat exchanger block 1390. The hot loop may also use a reservoir 1330, which is illustrated as a common reservoir 1330 in FIG. 13, but may be provided as two separate (hot and cold) reservoirs 1330 in some embodiments. Additionally, blower 1380 may be provided to bring the ambient air supply to radiator 1370.

Heat exchange block 1390 includes a cold loop heat exchanger 1320 (cool blocks), a TEC array 1340 arranged on both sides of cool blocks 1320 and a hot loop heat exchanger 1350 (hot blocks). Thus, TEC array 1340 may transfer heat from the cold loop (through cool blocks 1320) to the hot loop (through hot blocks 1350), cooling fluid supplied to the garment 1310. Moreover, radiator 1370 removes heat from the system along with blower 1380. As illustrated, a double-ended system is provided, with TECs on both sides of the cool loop heat exchanger (cool blocks 1320). In an ambient environment of 115 (degrees) F., one may expect to achieve a drop of 60 (degrees) F. within the system. Controller 1345 controls TEC array 1340, decreasing or increasing the amount of cooling, responsive to both driver controls 1360 and electrical system 1355 (which supplies power, etc.).

One such heat exchanger which may be used in a system such as system 1200 is illustrated in FIGS. 14 and 15. FIGS. 14 and 15 illustrate an embodiment of a heat exchanger. Heat exchanger 1400 includes a cold cover 1410 (providing a space where cold fluid may be circulated), a cold plate 1420 and a TEC array 1430, providing an interface between cold fluid and the TEC array 1430. Thus, TEC array 1430 may cool a fluid and radiate out heat.

Such a heat exchanger may be integrated with a hot fluid heat exchanger, arriving at heat exchanger 1500. Cold cover 1510 is joined to cold plate 1520, providing a channel for cold fluid entering through inlet 1560 and exiting through outlet 1565. Cold plate 1520 is also joined to TEC array 1530. TEC array 1530 is also joined to hot plate 1590 and to hot cover 1550, providing a channel for circulation of hot fluid which may enter through inlet 1570 and exit through outlet 1575.

To aid in cooling, a fan may be used in various embodiments. FIG. 16 illustrates an embodiment of a fan. Fan 1600 is suitable for mounting in places where a secure mount is needed. Fan 1600 includes a housing 1610, fan blades 1620, a mounting component 1630 and a motor and electrical interface (not shown). Fan 1600 may thus be mounted in an environment such as a vehicle, and powered to blow ambient air across a TEC array, radiator, or other heat exchanging surface. Fan 1600 is a relatively conventional component.

FIG. 17 illustrates an embodiment of a heat exchange block, in assembled (FIG. 17A), exploded (FIGS. 17B, 17C), and back views (FIG. 17D). Block 1700 includes a hot block 1710, cold block 1720 and hot block 1710, sandwiched around two TECs 1730. Each TEC 1730 includes leads 1737. Hot blocks 1710 include inlet/outlets 1717 and cool block 1720 likewise includes inlet/outlets 1727. Cool block 1720 includes channel 1725, for a cooling fluid. Hot blocks 1710 include channels 1715 for fluid circulation as well. TECs 1730 cool cooling fluid of cold block 1720, and exhaust heat into hot blocks 1710, where fluid therein transports the heat away. TECs 1730 may seal the channels 1715 and 1725, or the channels may be sealed by interposed components (e.g. metal sheets).

FIG. 18 illustrates another embodiment of a heat exchange block, in an assembled view (FIG. 18A), and with component views (FIGS. 18B, 18C and 18D). Hot blocks 1810 sandwich a pair of TECs 1830 which in turn sandwich a cold block 1820. Hot blocks 1810 include inlet/outlets 1815 and cold blocks include inlet/outlets 1825. Hot blocks 1810 also include an interior channel 1817 for fluid circulation, as do cold blocks 1820 with channel 1827. Alternative hot block 1850 is also provided, with inlet/outlets 1815 and interior channel 1817. TECs 1830 may seal the channels 1817 and 1827, or interposed seals may be used.

Example Embodiment

In one embodiment, the following describes the particular features of a cooling system using two loops to cool a garment such as for use in an automobile. The particular embodiment described may include features of other embodiments described herein, and features of this embodiment may be used with those of other embodiments described herein. Limitations of this particular embodiment may not apply to other embodiments.

The cooling system includes two closed loop fluid circuits. The primary cooling element(s) is a Peltier Device or thermoelectric cooler (hereinafter TEC) which may be used either individually or in an array to provide sufficient cooling to the “cold” fluid circuit. A “hot” fluid circuit is also provided to wick heat from the TEC array sufficient to allow the unit to deliver cold-circuit temperatures of between 45 and 65 degrees Fahrenheit.

The Cold circuit flow sequence is: Reservoir->Pump->Heat Exchanger Assembly (containing the TEC array)->External connections->Cooling Garment->Back to Reservoir. The Hot circuit flow sequence is: Reservoir->Pump->Heat Exchanger Assembly (backside of TEC array)->Radiator->Back to Reservoir.

Supporting Subsystems include: a blower, controller, controls, and an enclosure. The blower brings in fresh ‘ambient’ air to cool the fluid passing through the radiator and force stagnant hot air out of the enclosure. The controller is an electronics module (for example) controlling the pump(s), blower(s), thermocouples, and TEC array. The controls are driver controls and indicators allowing the (gloved) driver or passenger to operate the system. The enclosure contains the system components and may be designed for rapid installation and removal.

In one embodiment, the TEC array is a collection of Thermo Electric Coupling devices using the Peltier effect. These devices may be wired in series or parallel in order to obtain the desired current draw for the application. An array of multiple devices is used to increase the surface area through which heat may be extracted from the cold fluid circuit. When activated, the array pulls heat from the cold fluid circuit and pushes heat into the hot fluid circuit. In this way, the TEC array effectively operates as a large surface area solid state heat pump.

The heat exchanger assembly, in one embodiment, is a collection of engineered plates, specific covers, gaskets, and fittings which allow the TEC array to pump heat from the cold fluid circuit and move it to the hot fluid circuit. This assembly can be reconfigured to support a wide variety of TEC arrays. The components in the heat exchanger assembly include: a cold plate, cold plate cover, TEC array, hot plate, hot plate cover and seals.

The cold plate is an engineered metal plate (typically of Aluminum or Copper) designed to offer a maximum (essentially) amount of surface area through which heat is drawn from the cold fluid circuit. The entire plate is chilled by the TEC array as part of the assembly. The cold plate cover is an engineered cover for the cold fluid circuit side of the heat exchanger assembly. This component may be made of a thermally inert material such as plastic or lexan. It is configured to accept the cold fluid circuit fittings. The TEC array is a collection of Peltier devices arranged for essentially maximum surface area and wired for desired current draw.

The hot plate is likewise an engineered metal plate (typically of Aluminum or Copper) designed to offer a maximum (approximately) amount of surface area through which heat is drawn from the TEC array. The plate is warmed by the hot side of the TEC array and then the heat is drawn into the hot fluid circuit where it is cooled. This plate may be equipped with the necessary fittings to integrate into the hot fluid circuit. The hot plate cover is an engineered cover for the hot fluid circuit side of the heat exchanger assembly. This component may be made of any material but will typically be constructed from a thermally inert material such as plastic or lexan to prevent “heat soaking” the heat exchanger assembly. The cold and hot fluid circuits are sealed by way of gaskets or O-rings between the plates and their covers.

Supporting components include pump(s)—e.g. two pumping units propel the cold and hot fluid circuits. Flow should be approximately 2.5 e10-5 M̂3/S. Multiple motors or an external driving source may be used to rotate the pumping assemblies. Additionally, radiator(s) such as finned fluid channels are used within the hot fluid circuit to exchange heat to a charge of ambient air being passed through the enclosure by the blower. The surface area of the finned surface should be sufficient to keep the hot fluid circuit within ten degrees (10) F of the ambient temperature. Moreover, blower(s), such as high-velocity fan assemblies may be used for moving sufficient volumes of ambient air through the enclosure so that the radiator achieves its desired level of heat dissipation and so the enclosure will not rise in temperature as a result of operating in a hot environment. Typical inlet/outlet dimensions are between 1.5″ and 4″ diameters with flow rates between 120 and 240 cubic feet per minute.

External connectors provide interfaces between the system and the cooling garment and may be provided using leak resistant quick disconnects. For additional operator safety, these connections may become disconnected if a suitable force is applied to the connection without the need to actively disengage them via a button or spring release. In one particular embodiment, this force is approximately fifty pounds (50 lbs) of linear pull on the long axis of the connector. A sufficient volume of fluid may be contained within the unit, in a reservoir, to fill depleted cooling garments, vent gas bubbles from the fluid circuits, and provide a thermal balance to prevent rapid temperature swings. Also, an electrical control circuit can be included to receive power from the primary source and parse it out to the various system components including the TEC array, pumps, blowers, and controls and indicators. The unit may be equipped with adequate external connections to allow for wire and cable replacement without completely removing the system and/or controller.

Sufficient switch gear and indicators, either via lights or displays, allow the operator to activate the system and set a desired level of cooling. Additional functionality may include service modes, fluid level indications, and sufficient illumination to operate the system in low-light environments. The controls may be a panel or may be individually mounted within reach and view of the system operator and are connected back to the controller via an electrical umbilical carrying the control and feedback signals. The system components are contained within an enclosure (excepting the controller and controls and potentially the blower(s)) which provides protection from the environment and accidental damage to the system. The enclosure is typically thermally inert and offers thermal, shock, and fluid protection to the system components. The enclosure may include a method for rapidly installing and removing it from the operating environment—it may be designed for such installation and removal.

Other embodiments of similar systems may also be used. FIG. 19A illustrates another embodiment of a body temperature control system. System 1900 uses a compressor for heat exchange and cooling. System 1900 includes a cooling loop coupling a garment 1910, compressor 1920, pump 1930 and reservoir 1940. The compressor is further coupled to a radiator 1950 to assist in shedding excess heat. Compressor 1920 may be powered from an electrical system of a car, for example, or from other conventional power sources. Additionally, a control component (not shown) may be integrated to control operation of compressor 1920, and thus to vary the temperature of a fluid circulated in the cooling loop. The various components may be coupled through use of tubes or hoses, for example, and may operate to circulate cooled water to garment 1910, and then to cool water circulated from garment 1910. Compressor 1920 in conjunction with radiator 1950 provides a heat exchanger function in this particular embodiment, and may provide advantages in terms of power draw, for example.

In another embodiment, cool and hot loops are used. FIG. 19B illustrates yet another embodiment of a body temperature control system. System 1990 includes the components of system 1900 as described with respect to FIG. 19A. However, a hot loop is provided, with an additional pump 1930 and reservoir 1940 provided in a loop with compressor 1920 and radiator 1950—all of which are coupled together through use of hoses or tubes, for example. System 1990 may provide more efficient cooling in systems where the additional components may be incorporated effectively. System 1990 may also incorporate control and power supply components (not shown), for example. Compressor 1920 provides a heat exchanger function in this embodiment in conjunction with the cold and hot loops.

One may also implement a heat exchanger through use of a compressor in conjunction with a TEC or Peltier device. FIG. 19C illustrates an embodiment of a heat exchange block in block diagram form. Heat exchanger block 1925 includes compressor 1970, fluid line 1975 and TEC 1980. Compressor 1970 is coupled to a fluid transfer line 1975 to cool line 1975. TEC 1980 is also coupled to line 1975, and may operate to oppose compressor 1970. Thus, TEC 1980 may provide for fine tuning of the temperature imparted to line 1975 in some embodiments.

The embodiments of FIGS. 19A, 19B and 19C may have various physical forms. FIG. 19D illustrates a perspective view of an embodiment of a body temperature control system as it may be arranged physically. System 1901 includes a compressor 1920, controller 1957 (controlling the compressor 1920, e.g.), condenser 1967, heat exchanger 1947, shell 1937, suit connections 1927, air inlet 1917, and exhaust air slats 1907. Compressor 1920 is mounted on shell 1937 and is controlled by controller 1957. Compressor receives air from inlet 1917 via condenser 1967, and provides cooled refrigerant to heat exchanger 1947. Heat exchanger 1947 receives and sends coolant fluid through suit connections 1927 (e.g. barbs provided in through-holes of shell 1937). Exhaust air slats 1907 allow for cooling of compressor 1920. Coolant fluid may be entirely separate from refrigerant, for example, such that a typical refrigerant may be used with compressor 1920, for example.

FIG. 19E illustrates another perspective view of the embodiment of a body temperature control system of FIG. 19D. Note that pump 1930 is also illustrated, providing a mechanism to cause fluid flow between heat exchanger 1947 and a garment (not shown). Additionally, reservoir 1940 is illustrated, attached to shell 1937—reservoir 1940 may be used with the coolant fluid, for example. Also, fan 1917 may be provided as part of inlet 1917 (the fan may be an integral part of the inlet). Moreover, controller 1957 may be an interface between compressor 1920 and such systems or components as an electrical system of a car and/or a driver control component, for example.

Various garments may be used with the systems described. FIG. 20 illustrates an embodiment of a shirt, in front (FIG. 20A) and back views (FIG. 20B). Shirt 2000 provides one such example. Shirt 2000 includes fabric layers 2010 and a bladder 2100. Bladder 2100 includes, in one embodiment, die cut foam 2020 (providing a relatively incompressible layer with space for fluid flow), barriers 2030 (which may provide structural stability, isolation, and/or direction to fluid flow), tube 2040, inlet 2050 (coupled to tube 2040) and outlet 2060 (provided at the bottom of bladder 2100 in this embodiment). Bladder 2100 allows for fluid flow within a confined part of shirt 2000, and is either encased in fabric layers 2010 or attached to a fabric layer 2010.

FIG. 20A illustrates an embodiment with a single inlet 2050 and outlet 2060, with coverage for most of the torso. FIG. 20B illustrates an embodiment with multiple inlet 2050/outlet 2060 pairs, associated with two regions separated by barriers 2030. In one embodiment, FIG. 20A illustrates the front of a shirt and FIG. 20B illustrates the back of a shirt.

FIG. 21 illustrates an embodiment of a bladder of the front of the shirt of FIG. 20. Likewise, FIG. 22 illustrates an embodiment of a bladder of the back of the shirt of FIG. 20. FIG. 21 illustrates an embodiment where valves 2050 and 2060 are coupled to tubes 2040 further away from bladder 2100. Additionally, a tube 2040 for outlet purposes is provided in an outlet portion of die cut polyurethane 2020. FIG. 22 likewise illustrates an embodiment in which tubes 2040 lead to inlet and outlet components not shown, through passages in die cut polyurethane 2020.

FIG. 23 illustrates an exploded perspective view of the bladder of the back of the shirt of FIG. 20. FIG. 24 illustrates an exploded perspective view of the bladder of the front of the shirt of FIG. 20. FIG. 25 illustrates an exploded perspective view of a bladder such as the bladders of FIGS. 23 and 24. Reference to FIG. 25 makes it apparent that such a bladder (e.g. bladder 2500) may be constructed as part of a shirt, with an outer shirt layer 2510 attached to a thermoplastic polyurethane layer 2520. A die cut polyurethane layer 2530 is then provided, with tubes or hoses 2535 also provided in appropriate locations for fluid distribution. The die cut polyurethane layer 2530 is sized to be thick enough to allow for fluid flow within voids in the layer, and is dense enough to be relatively incompressible, even under pressure such as that created by a seat harness in a car. Die cut polyurethane layer 2530 is sonic welded to layer 2520 and also to layer 2540, providing a sandwich that seals any fluid separately from the surrounding shirt layers. Inner shirt layer 2550 is attached to layer 2540, and is a wicking layer which takes moisture from a wearer of the garment in some embodiments.

FIG. 23 illustrates a similar structure, with thermoplastic polyurethane layers 2310 and 2320 of bladder 2200 welded on both sides of die cut polyurethane 2020. Welding occurs along weld area 2025. Tubing 2040 is placed within the voids of polyurethane 2020, providing for distribution of fluid. FIG. 24 illustrates yet another similar structure. Layers 2410 and 2420 provide the outer thermoplastic polyurethane layers for bladder 2100. In FIG. 23, the bladder 2200 may be useful for a back of a shirt, whereas in FIG. 24, the bladder 2100 may be useful for the front of a shirt in one embodiment. Other materials may provide a relatively incompressible space for fluid flow in a bladder of a garment. Moreover, other assembly methods may be useful, such as simply containing a bladder within a sewn or otherwise enclosed portion of fabric of a garment, for example.

Another option for a garment is a vest or similar garment with a bladder contained therein. FIG. 26 illustrates another embodiment of a garment in the form of a vest. Vest 2600 includes an outer layer 2610 (which may be an insulating layer), and inner layer 2630 (which may be a wicking layer, for example) and inlet/outlet ports 2620. Not shown is a bladder which may be provided using a bladder layer. FIG. 27 illustrates a top view of the vest of FIG. 26 as laid flat. It is apparent that the inlet/outlet ports are relatively far from each other on the vest 2600 in this view.

FIG. 28 illustrates an exploded view of the vest of FIG. 26. Vest 2800 corresponds to vest 2600, with an inner layer 2830, bladder layer 2820 and outer layer 2810. Inner layer 2830 is a wicking layer useful in removing heat and moisture from the skin of a wearer. Outer layer 2810 is an insulating layer which keeps excess heat out. Bladder layer 2820 provides a relatively incompressible bladder which allows for fluid flow even under some compressing forces or loads (e.g. a harness in a car, or a person lying on the material). In one embodiment, bladder layer 2820 is provided using a plastic mesh available from Kuchofuku of Japan. The plastic mess is relatively incompressible, and can be attached to wearable outer and inner layers 2810 and 2830. Outer layer 2810 may be made of various materials, such as rip-stop nylon, leather, vinyl, and potentially a treated cotton product, for example. Inner layer 2830 may be a wicking material such as Wicker's brand fabric or a cotton or polyester blend material. It may be preferable to treat inner layer 2830 with a flame retardant chemical or process, such as Akwatek.

Example Embodiment

In one embodiment, the following describes the particular features of a garment which may be used in a cooling system. The particular embodiment described may include features of other embodiments described herein, and features of this embodiment may be used with those of other embodiments described herein. Limitations of this particular embodiment may not apply to other embodiments.

The human body's natural mechanism for maintaining body temperature, and particularly, cooling the core temperature is a two phase process. In part one; warm blood is circulated to the extremities (hands, ears, and feet) to promote the radiation of heat into the environment. In part two; sweat is produced to wick heat away from the body via an evaporative effect. Existing cooling garments ignore the second component (part) of the body's cooling process. While they absorb and remove heat from the surface of the skin, the existing garments do not allow surface moisture to evaporate. This leaves the wearer uncomfortably moist and sweaty—and no cooler from their perspiration. Thus, it may be useful to produce a garment which complements the body's natural mechanisms by: 1) providing a cooler fluid into which heat may be radiated as well as 2) providing a mechanism to remove moisture from and around the body.

One option is to provide a garment that creates a gap or airspace around the body through which conditioned air or another fluid may be circulated and eventually exhausted. This will provide a cooler (assuming a cooling mode) fluid into which the body may radiate excess heat and will provide a mechanism for stripping the wearer's body and undergarments of moisture. The airspace is created by placing a suitable mesh between two layers of fabric or material which is: relatively incompressible under the forces of normal use while simultaneously allowing air or another cooling fluid to circulate through the mesh, in contact with both the inner and outer layers of the garment.

Ambient air is passed through an air cooling device, such as those described with respect to various embodiments above. This filtered and chilled air is then passed to the garment via insulated hoses. The hoses connect to the garment via positive-locking or magnetic-retention, for example. The chilled air enters the garment and passes through the middle layer. The Inner layer wicks heat and moisture from the wearer's body and passing it to the middle layer. As the chilled air circulated around the garment, it carries the heat and moisture with it until it is exhausted. This warm and moist air is now exhausted via pre-determined exit points in the garment, taking the heat and moisture into the ambient air outside of the wearer and garment. In the case of a cooling fluid, moisture can be absorbed in other ways, such as in a reservoir or ducted out separately.

The Garment which makes this possible includes an inner layer, a middle layer and an outer layer. The inner layer (against the body) includes a wicking fabric which is comfortable, flexible, has elastic qualities, and which pulls moisture from the wearer's skin toward the middle layer (the airspace). Potential materials include: Wicker's brand flame resistant fabric and a number of cotton and polyester blends which may be treated with Akwatek or a similar chemical process. This layer may also be flame resistant and may not emit noxious fumes when charred.

The middle layer (airspace) Is filled with a ‘plastic mesh’ which is not crushable and allows for air to flow through the middle layer even when the garment is compressed, twisted, and folded as part of normal use. Other materials providing a similar set of properties may be used. This layer may be made of a light weight material which does not readily decompose or have its physical or chemical properties significantly altered in the presence of sweat and moisture. An example of this layer would be plastic mesh available from Kuchofuku of Japan.

The outer layer (furthest from the body) is a non-vapor permeable and durable exterior shell which protects the interior of the garment, provides fastening for patches, connections, and is a surface for branding and design elements. Potential materials for this layer include: rip-stop nylon, vinyl, leather, and a number of treated cotton products.

A further note on the plastic mesh. The product available from Kuchofuku is a plastic mesh of interlocking open-sided cubes which are linked via small tabs. The cubes themselves are capable of supporting the weight of a man when that weight is spread over sufficient area. The open sides of the cubes allow air to flow through the fabric in the X and Y planes without the air having to exit the fabric via the Z plane (air can flow laterally without penetrating the side walls of the mesh). The mesh is flexible in twisting and folding making it comfortable to wear as it conforms to the body's natural curves. However, it is able to withstand compression as long as the user's weight is distributed across a sufficient area. Fresh air is motivated through the middle layer, where it absorbs heat and moisture, and is then exhausted via an exit point in the product.

Other embodiments of various components may be used in the systems described above. FIG. 29 illustrates yet another embodiment of a heat exchanger. Heat exchanger 2900 may be useful with the systems of FIGS. 19A-19E, for example. FIG. 29 provides a top view (FIG. 29A), perspective view (FIG. 29B), side view (FIG. 29C) and front view (FIG. 29D). Other views are omitted to avoid unnecessarily obscuring details of the component.

Exchange block 2900 includes fluid channels 2910, fluid barbs 2920, a suction line and cap tube 2930, and a copper block 2940. Fluid channels 2910 are formed within copper block 2940. In one embodiment, fluid channels 2910A is formed in a top portion of copper block 2940, and is connected to fluid barbs 2920 to provide for inlet and outlet connections. Fluid channel 2910A is used with coolant fluid (such as water) which is circulated to and from a garment. Fluid channel 2910B is formed in a lower portion of copper block 2940, adjacent to fluid channel 2910A. Fluid channel 2910B is used with suction and cap lines/tubes 2930 to exchange refrigerant fluid with a compressor, for example (e.g. as an expansion area for refrigerant fluid). Refrigerant fluid in channel 2910B cools copper block 2940, which in turn cools coolant fluid in channel 2910A. A fluid cap 2950 is placed over fluid channel 2910A (potentially covering and sealing channel 2910A), and fluid cap 2950 may be plastic or another inert material, for example. Evaporator cap 2960 is placed beneath fluid channel 2910B (potentially covering and sealing channel 2910B). Evaporator cap 2960 may be copper, for example, to support brazing. Note that other materials may be useful in this heat exchanger, for example.

Additional embodiments may be used with a different garment design as shown and described. In one embodiment, a personal cooling garment is provided. The personal cooling garment is designed to work with both specific predetermined cooling systems such as those described in the embodiments above, and with other cooling systems designed to extract heat from the human body by passing a cooled fluid near the surface of the skin.

In one embodiment, a fluid-based heat exchange system which puts the cooling fluid in much more intimate and broader contact (or proximity) with a wearer's body than other systems is provided. In addition, a garment used in the system leverages wicking techniques to move warm moisture away from the wearer. Moreover, the construction of the garment potentially lends itself to easier maintenance, reduced wear and tear on the product, improved comfort in automobile racing environments and similar compressed or confined environments, and offers superior thermal exchange when compared to current liquid based solutions available on the market today.

Some of the features of the garment used in the system in some embodiments include use of a bladder, foam standoffs, high performance fabric and high efficiency tubing. Each of these features will be discussed in turn. The bladder system involves passing cooling fluid across the wearer's body via a bladder system, as opposed to flowing through plastic tubing. The bladders can be constructed of multiple layers of TPU (thermoplastic polyurethane) film, between which the cooling fluid is passed and routed. Relative to other systems, such a system can provide greatly increased surface area. When compared to tube options, the bladder provides as much as 20 times the surface area for thermal exchange. Moreover, this can provide more intimate contact. Single-layer TPU film is used to place the cooling fluid as close to the wearer's skin as possible while providing greater flexibility to conform to the wearer's body shape.

Additionally, such a construction can provide for force distribution. For those who would wear the garment while seated or in a compressed situation, the broad surface of the bladder more evenly distributes force loads. This reduces the likelihood of developing uncomfortable pressure points and increases the overall comfort for the wearer when exposed to situations such as being strapped into a racing seat, constantly jostled as in off-road racing, for prolonged periods of time as a heavy-machine operator, or when lying for prolonged periods of time on the back or stomach. Moreover, such force distribution potentially decreases or eliminates pinch-off effects and similar fluid flow blockages.

The garment construction can be anti-microbial in nature as well. As the film used to create the bladder system discourages the growth of bacteria, the product better copes without being drained, and is less likely to clog itself or supporting systems after extended periods of non-use. The garment as illustrated (see, e.g. FIGS. 20A and 20B, 30, 32, etc.) also provides for a gravity-drain feature. When hung from a designated draining point on the bladder, the bladder will tend to drain, with the outlets at the lowest point(s) of the bladder. This potentially encourages proper maintenance and simplifies purging the bladder. The bladder has a multi-channel arrangement. Cooling fluid is allowed to flow throughout the bladder via a large number of potential paths. This potentially allows for maximum surface area and promotes optional routing around any potentially pinched or obstructed paths where fluid flow may be restricted. Also, the bladder provides breathing holes. An arrangement of holes through the bladder promote and allow for the natural escape of heat and offer a chance for the wicking material of which the garment is constructed, to operate within the footprint of the bladders. These features potentially reduce the weight of the bladder system as well.

In some embodiments, the bladder is removable and placed in a pocket within a garment (see, e.g. FIGS. 30 and 32). In other embodiments, the bladder is integrated within the garment. In such garments, fabric may penetrate the holes of the bladder (e.g. joining layers from opposite sides of the bladder through the holes), and thereby further promote wicking and heat transfer, for example.

The bladders discussed are supported by foam standoffs—a network of foam standoffs which provide a number of additional features. The foam standoffs can be made of a relatively incompressible celled foam, such as LD45 foam (a low density polyethylene foam, for example) available from a variety of manufacturers. The foam standoffs can provide thermal insulation, further isolating the cooling fluid contained within the bladder from external heat sources, and rendering the garment and cooling system more effective. The foam standoffs also provide flow protection, as arranged in the illustrated embodiments. The arrangement of the standoffs serves to keep the bladder channels open and flowing during compression of the garment thereby preventing or reducing blockage of flow.

Additionally, the foam standoffs can provide shock absorption. The foam offers padding and shock relief to loads which would affect the wearer. This is accomplished via the offset of two force loads. Loads perpendicular to the surface of the foam standoffs are partially absorbed and normalized via the compressible qualities of the foam. Shearing loads parallel to the surface of the foam standoffs are partially mitigated allowing the wearer to experience reduced chaffing and rubbing when the outer surface of the garment may be enduring these loads in a greater magnitude.

Some embodiments of the garments also use high-performance fabric construction. The garments are constructed primarily of wicking fabric which encourages warm moisture to travel to the outer surface of the garment where it can be evaporated, contributing to wearer cooling. One example of such a fabric is available from Wickers of Commack, N.Y. Additionally, the fabric is flame retardant and does not easily ignite, melt, or burn continuously. Rather it chars while releasing a non-toxic smoke. Moreover, the fabric is particularly elastic, allowing the garment to accommodate many body types while encouraging the bladder system to be in intimate contact (proximity) with the wearer's body profile. In addition, the intimate contact of the material with the skin further enhances the wicking qualities of the garment. Other fabric can be used which may include some or all of these features. In particular, fabric may be used that has wicking properties, but may not have fire-retardant properties, for example. The garments may also be made using Aries Micro Plus Polyester available from Bone (Bushnell of Overland Park, Kans.).

Some embodiments of the garments and bladders also use high efficiency tubing. An arrangement of tubing is used to transport the cooling fluid from the cooling system to the bladder system (as with the system of FIG. 5, for example. The use of highly insulated tubing allows for the delivery of appropriately cool fluid to the bladder system. This promotes efficiency of the system, as the cool fluid can then absorb heat from the wearer. Multiple routing options may also be used. The tubes may be routed in one of many ways to promote cooling to the wearer's preference. Potential routing options include: front to back, back to front, split front/back (as illustrated in FIG. 30, for example), front only and back only.

Such tubing and associated connectors allow for effective disconnection. The tubing arrangement may be disconnected allowing for the removal of the bladders from the garment for replacement, maintenance, or laundering. These disconnect points may be user-serviceable, requiring no specialized tools or processes to disconnect and reconnect the tubing arrangement. Moreover, these disconnect points, the fluid inlet and outlet interfaces of the garment, are provided via ‘quick disconnect’ fittings. Such fittings can be managed with single-handed operation and seal upon disconnection to avoid or limit leakage and drainage of fluid. Moreover, such fittings allow for emergency break-away from a system (such as when a wearer in a racing vehicle needs to make a quick exit) without requiring a button press, for example. Additionally, such fittings may smooth the process of attachment to other cooling systems.

Reference to specific figures may further illuminate features of various embodiments. FIG. 30 illustrates an embodiment of a shirt that may be used with various system embodiments. Shirt 3000 includes an actual garment 3010, having a pocket 3020 with an overlapping fabric seam through which a bladder 3030 is visible. Inlet tube 3060 and outlet tube 3065 are connected to and part of bladder 3030, providing for inflow and outflow of temperature control liquid (e.g. cooling liquid). Another bladder (not shown) is provided in the back of shirt 3000, to which inflow tube 3040 and outflow tube 3045 are attached. Inflow connector 3050 provides a connection from a temperature control system such as that of FIG. 5, for example, to inflow tubes 3040 and 3060. Likewise, outflow connector 3070 provides a connection to such a system for outflow tubes 3045 and 3065. Thus, both bladders can be supplied simultaneously with temperature controlled fluid, allowing for temperature regulation.

FIG. 31 illustrates in FIGS. 31A, 31B, 31C, 31D and 31E, construction of a bladder for use in the shirt of FIG. 30 and other garments. FIG. 31A illustrates the bladder 3100 starting with die-cut foam 3110. Foam 3110 may be LD45 foam, for example, which is relatively incompressible and may be an open-cell polyethylene foam, for example. FIG. 31B illustrates bladder 3100 with foam 3110 mounted on layer 3120. Layer 3120 may be TPU, for example, which may be attached to foam 3110 in a variety of ways. FIG. 31C further illustrates bladder 3100, showing through-holes 3125 aligned between layer 3120 and foam 3110. Such through-holes 3125 may allow for communication of heat or fluids through bladder 3100.

FIG. 31D illustrates bladder 3100 with layer 3130 attached on top of foam 3110 and sealed along an exterior edge to layer 3120. Through-holes 3125 extend through layer 3130 as well. Also shown are inflow tube 3140 and outflow tube 3150. FIG. 31E shows bladder 3100 from the back (showing layer 3120). Also visible is seam 3160, which seals a portion of the internal channels of bladder 3100. Seam 3160 has the effect of forcing temperature regulated liquid from inflow tube 3140 to circulate through at least part of bladder 3100 before returning to an external system through outflow tube 3150. Bladder 3200, which may be used for a different portion of a garment, is also partially visible.

A bladder such as bladder 3100 of FIG. 31 may be used with a garment to provide a temperature controlled-portion of such a garment. FIG. 32 illustrates in FIGS. 32A, 32B and 32C, a combination of a shirt with a bladder in an embodiment. Illustrated in FIG. 32A is shirt 3250, including garment 3210 and bladder 3100. FIG. 32B shows shirt 3250 with the bladder 3100 inserted into pocket 3230 through opening 3220. Opening 3220 is provided through two overlapping pieces of fabric. FIG. 32C illustrates a closeup view of shirt 3250, with a portion of bladder 3100 visible through an opened opening 3220.

Other bladder designs may also be used. FIG. 33 illustrates another embodiment of a bladder. Bladder 3200 may be used in a back pocket of a shirt, for example. Bladder 3200 is shown with a top TPU layer 3330, seam 3360, inflow tube 3340 and outflow tube 3360. Seam 3360 constrains circulation to force some circulation through bladder of internal fluid. Not shown is a bottom TPU layer attached to layer 3330, or the internal material, which may be similar LD45 foam. Interstitial spaces 3335 are solid covers of holes in the internal foam. In this embodiment of a bladder, there are no through-holes as there are in bladder 3100 of FIG. 31.

As may be apparent, shirts such as shirt 3250 and bladders such as bladders 3100 and 3200 may be used with a cooling system. FIG. 34 illustrates another embodiment of a cooling system. System 3400 includes connective tubing 3410, pump 3425, heat exchanger 3430 and garment 3450 provided in a fluid communication loop. Reservoir 3420 is also provided, which may allow for expansion of circulating liquid or replacement of lost fluid. Heat exchanger 3430 may be a heat exchanger such as that illustrated in FIGS. 3 and 4 or one such as that illustrated in FIG. 29, for example. Controller 3490 controls heat exchanger 3430, and may be coupled to or include sensors, a power supply, and a user interface (not shown), for example. Pump 3425 pumps fluid through the fluid communication loop. Garment 3450 may be a garment such as shirt 3250 or shirt 510, for example. As illustrated, garment 3450 has a single inlet and a single outlet, but this may involve branches within garment 3450, or may involve a series connection of multiple bladders, for example, in garment 3450.

FIG. 35 illustrates another embodiment of a garment that may be used with a cooling system. Garment 3500 is a shirt which includes two bladders (front and back) through which cooling liquid (or generally temperature-controlled liquid) may be circulated. Illustrated is bladder pocket 3510 and coolant hoses 3520, which couple to a bladder (not shown) through a slot in bladder pocket 3510. Not shown is a bladder pocket on the other side of the shirt, with a corresponding slot in the fabric for coolant hoses 3520.

Coolant hoses 3520 are shown with quick-release connectors 3530, which are fittings that allow for easy disconnection from a temperature control system which circulates fluid through coolant hoses 3520. Such fittings may be fittings available from Colder of St. Paul, Minn., such as the PLC series of fittings for example. These fittings may work with tubing such as Norprene or Tygon tubing available from Saint-Gobain of France to provide a relatively incompressible fluid pathway. Other tubing and fittings may also function appropriately. Additionally, the fittings are generally open (allow fluid flow) when pressed by connected to a central system (and the appropriate fitting) and generally closed when only fluid on the inside of bladders of garment 3500 is present (and the appropriate fitting is not connected), for example. These fittings and hoses (tubing) may allow for use of the garment with systems other than those described in this document as well.

Bladder pocket 3510 is a pocket in the fabric of shirt 3500 which holds a bladder in place. In one embodiment, bladder pocket 3510 is sewn shut with the bladder contained therein. This may have the advantage of providing better support for a bladder than other designs may provide, for example. In other embodiments, the bladder may be accessed through a zipper or other fastener, for example.

A similar embodiment to that of FIG. 35 is illustrated in FIG. 36 (as FIGS. 36A, 36B, 36C and 36D). FIG. 36A illustrates a back view of an embodiment of a garment that may be used with a cooling system. FIG. 36B illustrates a front view of an embodiment of a garment that may be used with a cooling system. Garment 3600 includes a front bladder pocket 3610 and a back bladder pocket 3620. Contained therein are front bladder 3630 and back bladder 3640, respectively. Coolant hoses 3670 are coupled to bladders 3630 and 3640 through slots in pockets 3610 and 3620. Bladder pocket 3610 is sewn on to shirt front 3660 and bladder pocket 3620 is sewn on to shirt back 3650 in this embodiment. Other methods of forming the pocket may also be appropriate, such as through use of a pocket such as that shown in FIGS. 30 and 32C, for example.

FIG. 36C illustrates a cross-sectional view along a line A-A of an embodiment of a garment that may be used with a cooling system. As is apparent, the two bladders 3630 and 3640 are contained in the pockets 3610 and 3620, respectively. This arrangement can be used to effectively support the bladders 3630 and 3640 through use of the fabric of the garment 3600. FIG. 36D illustrates a cross-sectional view along a line B-B of an embodiment of a garment that may be used with a cooling system. As can be seen, coolant hoses 3670 are coupled to the bladders (not shown) through slots in each of bladder pockets 3610 and 3620, allowing for coolant to be circulated from a central system through the garment 3600.

The bladders and garments described above may be used in other systems and other applications, and may be used for both heating and cooling a wearer. Additionally, bladders may be formed in various different shapes and from various different materials, depending on the application. Thus, one may create a bladder suitable for use in a pant leg or for use in blanket, for example.

As another example, other materials may be used for a garment. Garment materials may include fabric with thermally conductive material weaved in or otherwise incorporated. Use of, for example, conductive material stitched into fabric may have beneficial effects. Likewise, natural fibers or synthetic materials of various sorts may be useful in such a garment in various applications. Other aspects of the embodiments illustrated and described may also be varied in keeping with the invention.

Another embodiment of a cooling block may also be incorporated in various systems. FIG. 37 illustrates in FIGS. 37A, 37B, 37C and 37D, an embodiment of a cooling block. Cooling block 3700 may be used for both cooling or heating a fluid that may be circulated through a garment such as a shirt. Block 3700 includes an internal cooling block 3710, heat spreaders (3740, 3770), external cooling blocks (3760, 3790), internal TECs (3720, 3730), and external TECs (3750A, 3750B, 3780A, 3780B). Cooling block 3700 thus provides for an inner and outer fluid loop which may be used to achieve two-stage fluid-based cooling. FIG. 37A provides an exploded perspective view of cooling block 3700. FIG. 37B provides a back view of block 3700. FIG. 37C provides a side view of block 3700 and FIG. 37D provides another exploded perspective view of block 3700.

Internal cooling block 3710 is provided as a center portion of cooling block 3700, and may be implemented as is shown in FIG. 38, for example. Coupled to internal cooling block 3710 are direct fluid contact TECs 3720 and 3730, with one in a lower position (below a channel of block 3710) and one in an upper position (above the channel of block 3710). Upper heat spreader 3740 covers TEC 3730 and the top of block 3710, providing a heat spreader that is thermally conductive, such as a plate of brazed copper, for example. Similarly, lower heat spreader 3770 covers the bottom of both TEC 3720 and the lower surface of block 3710, providing a heat spreader similar to heat spreader 3740 on the bottom of block 3710.

Connected to heat spreader 3740 are upper TECs 3750A and 3750B. Upper external cooling block 3760 covers and encloses TECs 3750A and 3750B and upper heat spreader 3760 (in one embodiment). Likewise, connected to heat spreader 3770 are upper TECs 3780A and 3780B. Upper external cooling block 3790 covers and encloses TECs 3780A and 3780B and upper heat spreader 3790 (in one embodiment). Block 3760 and block 3790 may be implemented as blocks such as those shown in FIG. 39, for example. Note that cooling block 3700 may be used for heating or cooling of fluid, with a simple switch in polarities of the TECs, for example.

FIG. 38 illustrates in FIGS. 38A, 38B, 38C and 38D, an embodiment of an internal cooling block of a cooling block. Block 3800 of FIG. 38 may be a cooling block such as internal cooling block 3710 of cooling block 3700 of FIG. 37, for example. FIG. 38A provides a top view of block 3800. Cooling block 3800 includes an internal chamber or passage 3820 contained within a block 3810. Block 3800 may be made from Delrin plastic, for example, providing an insulating block of material. Passage 3820 includes an inlet 3830 and an outlet 3840, both of which may be connected to tubes through use of barbs or other connecting components.

FIG. 38B provides a perspective view of block 3800. Shown here are shelf 3850 surrounding passage 3820 and providing a resting place for a TEC, which may be contained within chamber 3860 which is in turn contained within the top portion of block 3810. Likewise, shelf 3870 provides a resting place or boundary for a TEC which may be held in chamber 3880 at the bottom of block 3810, directly below passage 3820. Thus, two TECs may be placed in proximity to or in contact with fluid circulating through passage 3820. FIG. 38C shows a back view of block 3800 and FIG. 38D shows a side view of block 3800. Not shown are mounting bolts and associated apertures or through-holes, or spaces for leads of a TEC or other contact points, which may be placed in positions appropriate to specific devices used in various embodiments.

Providing an additional stage of temperature differential are additional TECs placed in external cooling blocks. FIG. 39 illustrates in FIGS. 39A, 39B, 39C, 39D, 39E and 39F, an embodiment of an external cooling block of a cooling block. Cooling block 3900 may be used to provide external cooling blocks 3760 and 3790 of block 3700, for example. Block 3900 is made up of block 3910 which includes channels 3920A and 3920B, which are used for circulation of fluid. Shelf 3950 provides a shelf for a heat spreader such as heat spreaders 3740 and 3770 of block 3700, for example.

Shelves 3980A and 3980B provide shelves (or upper surfaces) for TECs which may be placed within block 3900 and held in place by a heat spreader, for example. TECs on shelves 3980A and 3980B may be in communication with (e.g. in contact with) passages 3920A and 3920B, or may be in contact with a wall of such passages (in the case of sealed passages), for example. Chambers 3990A and 3990B define the spaces in which such TECs may be held. Channels 3920A and 3920B also include inlet/outlets 3930A, 3930B, 3940A and 3940B, which may be used to connect the channels 3920A and 3920B to external portions of a fluid loop, for example.

FIG. 39A provides a bottom view of block 3900. FIG. 39B provides a perspective view of block 3900. FIG. 39C provides a back view and FIG. 39D provides a side view of block 3900. FIG. 39E provides a top view and FIG. 39F provides another perspective view of block 3900. Note that in some embodiments, channels 3920A and 3920B have wider passage widths on one end of the channel than on the other end of the channel. This may provide a Venturi effect, cooling or heating circulating fluid as a result of increasing or decreasing volume, in some embodiments.

Block 3700 and similar cooling blocks may be used in a system such as those described and illustrated in Figs. Xxx, for example. FIG. 40 illustrates another embodiment of a body temperature control system. System 4000 includes a cold loop 4010 and a hot loop 4070. Cold loop 4010 links a garment 4030 (or other object to be temperature regulated) to a reservoir 4050, pump 4020 and cooling block 4040 (a heating/cooling block) in a fluid loop, with each component in fluid communication with the next. Hot loop 4070 links cooling block 4040 with pump 4075 and reservoir 4050 in a fluid loop as well. Radiator 4080 may also be used in hot loop 4080 to achieve additional cooling.

Block 4040 may be a block such as that of FIG. 37. Block 4040 thus has a cold portion which is linked to cold loop 4010 and a hot portion which is linked to hot loop 4070. For a situation where cooling is desired, cool fluid circulates through cold loop 4010, bearing heat away from garment 4030. Warmer fluid circulates through hot loop 4070, taking heat from cold loop 4010 via block 4040 and radiating that heat through radiator 4080, for example. Fan 4090 may be employed to increase efficiency, for example.

Also shown is control/power module 4060. Control module 4060 receives power from a power supply 4065 and provides that power to block 4040, pump 4020, pump 4075 and fan 4090, for example. The power supplied to block 4040 may be supplied to included TECs in block 4040, for example. Control module 4060 may vary the amount of power supplied or may provide control signals to components as well, to control the system. Thus, pumps 4020 and 4075 may be regulated by speed or power, for example. Moreover, TECs in block 4040 may be regulated to increase or decrease an associated thermal differential. Control module 4060 receives control signals from control interface 4055, which may include both a user control interface (e.g. a driver interface in a car) and other control settings, such as switched settings internal to a system, for example. Control module 4060 receives power from power supply 4065, which may be a power supply of various types, including an automotive power supply (e.g. a 13.8V power supply), a building power supply (e.g. a 120V or 240V power supply, for example), or various other power supplies. In some embodiments, battery, solar, thermoelectric, piezoelectric, IR (infrared), magnetic, wind, chemical, static electricity, electrolysis, fuel cell, biological, and kinetic including motor and user/operator powered options may be used as a power supply.

Note that reservoir 4050 is illustrated as a single component with an internal division into reservoir 4050A (cold loop) and 4050B (hot loop). Reservoir 4050 may be fully or partially divided, allowing for use of a single reservoir of fluid for both loops. In some embodiments, this can allow for additional heat exchange. With a reservoir container which is sufficiently thermally insulating, the two loops may be kept distinct.

Controlling a system such as system 4000 may be done in a variety of ways. FIG. 41 illustrates an embodiment of a control interface for a body temperature control system. Control interface 4100 includes a power supply 4110, fuse 4120, switch 4130, circuits 4140 and 4150, and a common terminal 4160. In one embodiment, switch 4130 is a single pole, triple throw switch available from Carling Technologies of Plainville, Conn. In one embodiment, the 2GG series of switches from Carling Technologies is used. These switches allow for a series of settings, with a first setting of off, a second setting of circuit 1 (subcircuit 4140) on and a third setting of circuits 1 and 2 (subcircuit 4150) on. Thus, one may regulate the system such that only some or all of the available cooling capacity is used with such an interface.

As is illustrated, circuit 1 (subcircuit 4140) includes a TEC array 4165, cold pump 4170, hot pump 4175 and blower 4180. All of the components of subcircuit 4140 receive power when switch 4130 is activated. When switch 4130 is placed such that both circuits are active, subcircuit 4150 (a second TEC array) also receives power, increasing cooling capacity. Not shown is a switch configuration for switching from cooling to heating, which may be accomplished by reversing polarity of voltage inputs to TEC Array 4165 and TEC array 4150, for example. Moreover, not shown are additional safeguards such as temperature sensors, monitoring processor(s) or other components which may be incorporated.

In some embodiments, other options may be used for cooling or heat exchange. For example, one may choose to provide a heat exchanger which is used for fluids such as air, rather than water or a similar liquid. One may use a heat exchanger and a cooling device (or heating device) in various different configurations. Additionally, one may choose to provide temperature control for a shirt or garment as mentioned above, or for a helmet, for example.

In one embodiment, a product is designed to address a primary source of racing car driver overheating; the intake and respiration of abnormally hot air during the race. The breathing air available to a racing driver is often hot, polluted, and in relatively short supply when compared to standard conditions in a home, for example. This is the result of a few effects such as: restricted airflow in and out of the cockpit in racing cars, restricted airflow in and out of the driver's helmet, air intakes which are generally located close to the racing surface, air intakes passing near heated structures, and the generally hot and polluted conditions experienced when closely following another vehicle at high speeds.

The potential effects of drivers breathing this hot and polluted air can manifest in a number of ways ranging from simple discomfort and displeasure with the temperature and smell of the air to exacerbated and accelerated levels of driver dehydration and overheating. In an attempt to ameloriate these conditions, an embodiment was developed to reduce the temperature of the breathing air delivered to the driver, to increase the general flow and availability of fresh air to a driver wearing a safety helmet, and to filter contaminants in the breathing airflow. In one embodiment, the system generally consists of three components: a cooling module, a blower, and interconnecting hoses and interfaces.

The general arrangement of system components in order from air intake into the system to delivery at the driver's helmet is: duct/Inlet location->primary intake hose->cooling module intake->heat exchanger->cooling module outlet->secondary intake hose->filter element and blower->driver connection hose->helmet intake connection.

These components, in an embodiment, can be described as follows in the following paragraphs. A duct/inlet location is provided. This is the point at which outside air is taken into the system. In an embodiment, a NACA duct with a 3″ diameter port is exposed to the fresh air surrounding the vehicle. This component is designed to introduce a large volume of air into the system in a manageable way, without too much of an adverse affect on the aerodynamic characteristics of the vehicle. Most such ducts will have some affect on aerodynamics, but placement can be chosen based on vehicle design to reduce such an effect.

A primary intake hose, in an embodiment, is a 3″ diameter hose or duct cut to length appropriate to move the air from the inlet location to the blower. Its typical characteristics include resistance to deformation and failure at required thermal loading, wound reinforcement throughout its length to maintain a consistent cross-sectional diameter, and a coating of relatively soft and flexible material thereby allowing for more versatile routing and easier installation. It may be secured to the duct and blower at either end by means of fasteners such as zip-ties, hose clamps, adhesives, tape, or screws, for example.

The cooling module, in an embodiment, is an insulated enclosure and sealed cavity which allows for the installation of a heat exchanger in a way which puts the heat exchanger in direct contact with ice or ice-water. The cooling module includes a main body and a lid which is secured with rubber/elastic T-handled fasteners in one embodiment. The construction of the module is generally a plastic (e.g. polyethylene) shell which is filled with expanding foam to provide a highly insulating enclosure for the ice cavity. The cooling module may be formed using roto-molding, for example. In one embodiment, the module has an inlet and outlet port located on opposite sides to allow air in/out of the heat exchanger mounted within. In some embodiments, the cooling module itself may be secured to the vehicle by the use of straps routed through slots and reliefs on the module such that the lid may be removed without necessitating the removal or loosening of the strapping system. This feature allows for rapid re-filling of the ice cavity as the cooling module may remain firmly mounted to the vehicle. The cooling module further includes a cooling module intake, heat exchanger and cooling module outlet in one embodiment.

The cooling module intake, In one embodiment, is a 3″ diameter intake port on the cooling module sufficient to accept the primary intake hose and offer some feature for securing the hose to this port. Actual size may be slightly smaller to accommodate 3″ interior diameter hoses, for example. The heat exchanger, in an embodiment, is suspended within the ice cavity of the cooling module and is intended to move heat from the air-stream to the ice. In this way, air moving through the heat exchanger exits the exchanger significantly cooler as it passes out of the cooling module outlet. The exchanger, in an embodiment, is provided as an array of copper or aluminum tubes arranged in a dense circular array, fastened at either end to a copper or aluminum plate. The copper or aluminum plate has through-holes that correspond to the tubes, allowing air or fluid to pass through the plate. As air enters the cooling module intake location, it is pulled through one of the many passages (tubes) of the heat exchanger via suction developed by the blower. As the air moves through a tube passage within the heat exchanger, it is exposed to the walls of the tube and rejects heat through the tube wall. The exterior of the tube wall is in contact with ice/ice-water, which offers the thermal delta (significantly cooler) to motivate the heat rejection from the air. The cooled air or fluid is then collected at the cooling module outlet into a single 3″ passage for delivery to the filter and blower element.

The cooling module outlet, in an embodiment, is a 3″ diameter male outlet port on the cooling module sufficient to accept a secondary intake hose and offer features sufficient to fasten the hose securely to the port. Actual diameter may be slightly smaller to accommodate 3″ interior diameter hoses, for example. A secondary intake hose, In an embodiment, is another 3″ interior diameter hose connected to the cooling module outlet port and to the filter/blower inlet. It is flexible and designed to allow for easy and varied placement of the blower/filter element.

The blower/filter element, in an embodiment, motivates air through the system using an axial fan (blower) powered by the vehicle's electrical system at approximately 13.8 VDC. This air-stream itself will be modified by both the blower and the filter. For the blower, in an embodiment, this device may have a 3″O.D. inlet and a 1.5″O.D. outlet to support the ingestion of air from the cooling module outlet, its acceleration/pressurization, and delivery to the driver's helmet via a 1.5″ diameter flexible hose. Air speed may be varied by the driver using a rotary knob or multi-position switch which affects simple circuitry related to the voltage supplied to the electrical motor of the blower. For the filter, in such an embodiment, this component will be located at or near the blower inlet and is intended to remove large and small particulate matter and may further condition the air through the offset, alteration, or removal of vapors and other chemicals such as carbon monoxide and fuel or exhaust fumes. The filter element can be of a disk or wafer shape having dimensions of approximately 3-4″ in O.D. with a thickness of approximately 1″ in some embodiments.

Also provided is a driver connection hose. In an embodiment, this is a 1.5″ interior diameter flexible hose which carries the cooled and filtered air to the driver helmet intake port. It may be chosen to be flexible to allow for easy routing and attachment. A spiral wound or accordion-style hose may be used, for example.

Reference to the figures may provide a greater understanding of various embodiments. FIG. 42 illustrates another embodiment of a cooling device in perspective view. Cooling device 4200 is intended for use with fluids such as air (or potentially fluids in liquid form). As illustrated, cooling device has a lid 4210, body (enclosure) 4220, inlet 4230 and outlet 4240. In one embodiment, lid 4210 and body 4220 collectively provide an essentially airtight container. Inlet 4230 and outlet 4240 allow for flow of air into and out of the cooling device 4200.

FIG. 43A illustrates another view of the cooling device of FIG. 42 in perspective view with visibility of interior components. As can be seen, heat exchanger 4250 is provided inside of cooling device 4200, mounted between inlet port 4230 and outlet port 4240. FIG. 43B illustrates yet another view of the cooling device of FIG. 42 in perspective view with a top removed. As can be seen, internal void or cavity 4260 is provided, with heat exchanger 4250 placed within the space of void 4260. Ice, or another cooling or phase change material, can be placed into void 4260 to extract heat out of (or put heat into) heat exchanger 4250. As is apparent, heat exchanger 4250 is a bundle of tubes or pipes mounted on plates at each end (inlet port 4230 and outlet port 4240). In a situation where ice is used, ice may interstitially occupy space between tubes, and water may likewise occupy such spaces, resulting in thermal conduction to/from the heat exchanger 4250.

FIG. 43C illustrates another view of the cooling device of FIG. 42 in a top view with visibility of interior components. FIG. 43D illustrates another view of the cooling device of FIG. 42 in a side view with visibility of interior components. Note that slots 4270 are provided which may be used for securing top 4210 to body 4220, or for routing of mounting straps, for example.

The heat exchanger 4250 has been discussed above, and is further illustrated in FIGS. 44A-C. FIG. 44A illustrates a view of the heat exchanger of the cooling device of FIG. 42 in perspective view. FIG. 44B illustrates a view of the heat exchanger of the cooling device of FIG. 42 in a top view. FIG. 44C illustrates a view of the heat exchanger of the cooling device of FIG. 42 in a side view. Copper or aluminum tubes may be used, for example, to provide a transport mechanism for a fluid such as water or other coolants passing through a cooling medium such as ice. The conductive nature of the tubes allows for transfer of heat out of the heat exchanger and into a cooling medium (or in the opposite direction for heating). As mentioned above, metal plates can be used at the interface between the tubes and the larger ports 4240 and 4250, providing an essentially air/water-tight seal. Such plates (discussed above) will be understood to one having skill in the art from the context of the illustrations and discussion.

The cooling device of FIGS. 42-44 can be used in various embodiments. FIG. 45A illustrates another embodiment of a cooling system, using the cooling device of FIG. 42. System 4500 includes an intake duct 4510 (shown in a cutaway perspective view) coupled to cooling device 4200, blower/filter 4520 and helmet 4530. This system takes in outside air at duct 4510, cools it through cooling device 4200, forces the air to flow as a result of blower/filter 4520 (and filters the air) and then delivers the cooled, filtered air to a driver via helmet 4530. Vents in helmet 4530 may allow for exhausting of air into the environment (and potentially may provide secondary cooling/conditioning in a closed environment). FIG. 45B illustrates the embodiment of a cooling system of FIG. 45A in schematic form. Note that other components can be used to provide the functions of intake, heat exchange, blowing/filtering, and delivery (helmet).

In one embodiment, which has been tested, the exterior dimensions of the lid and enclosure are approximately 17″×10″×9.5″ with an empty weight of 8 lbs (3.6 kg). This allows for an ice capacity of 4 lbs (1.8 kg). The power draw can range from 0.5-2.5 A in a typical 13.8 V system. An air filter is also provided for optional installation.

In this embodiment, a system is provided which delivers a temperature drop of 40+ degrees (F.). Such temperature drops can be sustained over a period of 3 hours from 4 pounds of ice in such an embodiment. A flow rate of the air can be selected by a driver through use of a control adjusting operation of the blower in such an embodiment. Air tight seals and rubber T-handles are used to lock the lid in place in such an embodiment. Additionally, the enclosure design insulates and increases ice life relative to prior systems in such an embodiment. These features result in lower power draw than prior systems in such embodiments as well.

In another embodiment, cooling of fluids is provided with a focus on a water or liquid-based system. Whether water itself, or a coolant fluid such as glycol is used, the system may be designed with a heat exchanger and overall system which improves upon performance of systems currently in the market. In one embodiment, a system is provided to address the primary drawback of conventional ice-chest based systems deployed for race car driver cooling. This drawback is the relatively short timeframe in which the system delivers sufficiently cool water to the driver, typically 45 minutes under racing conditions. The system may be expected to extend the amount of time which an ice-based driver cooling system could be used without significant changes to the packaging weight and exterior dimensions of prior systems. To accomplish the goal above, the system in some embodiments exchanges potential cold fluid temperatures for run-time. In one embodiment, the system delivers slightly warmer temperatures for greatly extended periods of time, potentially 1.5 hours or more using a similar or smaller quantity of ice to prior systems.

A system flow description (flow through a loop) in one embodiment can be provided as: First, water flows vertically down from the reservoir cavity through a first port to fill the fluid system as air is purged via a second port from the fluid system into the reservoir cavity via the double-T. Next, water flows via the fluid system to the pump inlet. Water then flows from the pump outlet to the heat exchanger Inlet via the system plumbing and interface barbs described below. Next, the water loses heat while it is pumped through the heat exchanger. The heat exchanger is covered/submerged by ice/ice water.

Thereafter, the water flows out of the system via the panel-mount quick-disconnect fittings to the cooling garment where it is passed over the driver. The water then absorbs heat from the driver and flows back into the system via the panel-mount quick-disconnect fittings where it is delivered to the inlet of the double-T. The process is repeated in this closed-loop system wherein water continues to be cooled via the heat exchanger, any air in the system is purged via the double-T. Deficiencies in water volume are filled via the double-T, and heat continues to be wicked off of the driver via the cooling garment.

Primary system components in one embodiment include a system enclosure, enclosure lid, ice cavity, reservoir cavity, systems cavity, heat exchanger, pump, electrical control system, and a mounting system. The system enclosure resembles an ice chest, though it contains multiple cavities (described below). It is designed with a primary focus on thermal isolation and is typically constructed of polyethylene with voids filled with expanding two-part foam. The enclosure lid is designed to allow easy access to the ‘Ice’ and ‘reservoir’ cavities. It can be completely removable, and may be secured with rubber ‘pull’ fasteners which provide shock absorption while maintaining a water-tight seal with the system enclosure.

The ice cavity is a void within the system enclosure and is the primary holding area for system ice. The cavity is constructed with baffles in place to discourage ‘sloshing’ of the ice or water during the course of a race. At its bottom, the cavity offers a mounting area for the heat exchanger and barbed fittings to accommodate system plumbing. The cavity is made water-tight by the enclosure lid and is accessed from the top of the enclosure. The reservoir cavity is another void within the system enclosure and is the primary holding area for system fluid used as the thermal transfer medium between the cooling system (particularly the heat exchanger) and driver cooling garments. It has sufficient capacity to completely fill multiple cooling garments and is easily filled by the user when the enclosure lid is removed. When the enclosure lid is in place, this cavity is also water-tight and is accessed from the top of the enclosure. There are two ports at the bottom of this cavity which allow the fluid, typically water, to fill the fluid loop and to purge air from the fluid system. The cavity is shaped in a manner which promotes the pooling of fluid near the ports at the bottom of the cavity to encourage proper system filling.

The systems cavity is yet another void in the enclosure, located and accessed via a side of the system enclosure. The systems cavity houses the fluid pump, double-T, external plumbing fittings, internal plumbing fittings, and the electrical connections for the system. It includes two ports on the top face which allow for fluid passage up to the reservoir cavity. It includes two ports on the interior face which allow for fluid passage in/out of the heat exchanger. It includes two panel mount fittings which allow for fluid passage in/out of the system to the cooling garment. It includes one wiring port to allow for power and control circuit wiring in/out of the system. It is enclosed via a removable service panel. This service panel may be ported/drilled or otherwise fashioned to promote air-exchange around the pump housing under racing conditions.

The heat exchanger may be a coil or array of metal channels, typically of copper or aluminum. The heat exchanger allows for the flow of system fluid through the ice cavity where heat is drawn from the fluid through the heat exchanger. The heat exchanger is generally in direct contact with the ice/ice water (typically a mixture of ice and water); typically being completely submerged and/or covered by ice during operation. The exchanger provides for sufficient surface area such that the system fluid leaves the exchanger at a useful temperature, often above 0 degrees Celsius, but cold enough to promote driver cooling. A typical range of 5-13 degrees Celsius is measured in one embodiment.

Also provided is a pump. A single pump can be employed to motivate fluid flow throughout the system. It is driven using a single or variable voltage derived from a vehicle's 13.8 VDC alternator/battery power source. It is turned on/off and modulated via an electrical control system. An electrical control system is also typically provided. Various systems can be used, to provide the following features:

Driver control of the system—achieved through the use of switches or potentiometers whereby the state (on/off) of the system and its performance is designated by the operator.

Safety mechanisms—includes fusing, rollover-detection, pump failure, and other safety triggers based on fluid and ice capacities, cooling garment connectivity, under/over voltage situations, and any other scenario under which system performance may be compromised or harmful to the racing platform, operator, or any crew interacting with the racing platform or cooling system.

Power connections—wiring, connectors, and associated hardware sufficient to connect the cooling system to the racing platform's power supply including alternator, battery, solar cell, or any other source of the required DC voltage.

Also included is a mounting system. A system of straps and receivers integrated into the system enclosure allows for the positive mounting of the cooling system to the vehicle such that it will pass relevant technical specifications for the series (racing series, e.g.) and will provide a measure of containment and safety should the system be installed in a vehicle which is involved in an impact, rollover, or other abnormal circumstance whereby the cooling system may become moved from its intended mounting position. The straps may typically be constructed of a Nylon material and are often terminated and attached to the vehicle using steel hardware sufficient to support the loads which the system may generate in any impact. This may be expected to keep the cooling system firmly installed in its intended location.

More details may be understood with reference to the drawings. FIG. 46A illustrates yet another embodiment of a cooling device in a top view with an open lid. Cooling device 4600 includes a lid 4610, enclosure (body) 4620, fluid reservoir 4650 and heat exchange chamber 4660, among other features. Inlet (4630) and outlet (4640) ports are shown on one side of the enclosure 4620. Also shown are ports 4655 of the fluid reservoir 4650 and internal dividers 4670 of the heat exchange chamber 4650. Not shown is a heat exchanger in the heat exchange chamber 4660, among other items.

FIG. 46B illustrates the cooling device of FIG. 46A in perspective view with a closed lid. FIG. 46C illustrates the cooling device of FIG. 46A in perspective view with an open lid. FIG. 46D illustrates the cooling device of FIG. 46A in a side view with an open lid. FIG. 46E illustrates the cooling device of FIG. 46A in a perspective view with an open lid. Note that plate 4680 is provided to block access to internal components of the cooling device 4600, in this embodiment with a ventilated portion of the plate allowing for air circulation in a void behind plate 4680.

FIG. 46F illustrates another embodiment of a cooling device in a perspective view with a closed lid. This embodiment of cooling device 4600 is functionally the same as that of FIGS. 46A-E. However, also shown are pump 4685 and double-T 4695, which are provided in cavity 4675. Double-T may be expected to mate with or be coupled to the pump 4685, to the ports 4655 of fluid reservoir 4650 and to one of inlet port 4630 or outlet port 4640, for example. Also shown are a handhold indent and slots for securing the system 4600.

FIG. 46G illustrates the cooling device of FIG. 46A in a cutaway perspective view with an open lid. In this embodiment, a single divider 4670 is provided in heat exchange chamber 4660 in the form of a metal plate. Additionally, a heat exchanger 4690 is provided in the form of a metal tube or pipe which is in contact with divider 4670. Divider 4670 in this instance may provide additional thermal conductivity. Also shown are locking T-handles 4615 on lid 4610 and a different configuration of inlet (4630) and outlet (4640) ports. Note that such ports may be interchangeable in some embodiments.

FIG. 46H illustrates the cooling device of FIG. 46A in a top view with an open lid showing some hidden components in a schematic illustration. Included in this illustration is a schematic representation of a heat exchanging coil 4690, with inlet and outlet pipes which mate with ports in the side of heat exchange chamber 4660 (ports not shown to avoid further obscuring the illustration). Heat exchanger 4690 may take on a variety of different forms or types. For example, a more complex topology winding through more of the heat exchange chamber 4660 may be used.

FIG. 47A illustrates an embodiment of a cooling device such as the cooling device of FIG. 46A in a side view. FIG. 47B illustrates the cooling device of FIG. 47A in a side view with flow illustrated. Device 4700 is a similar embodiment to cooling device 4600, and features of one such embodiment may be incorporated in the other. As shown, double-T 4710 mates with ports 4655 of fluid reservoir 4650, allowing air to travel upward into reservoir 4650 and replenishing fluid to travel downward into double-T 4710 (and thus into the coolant fluid stream). Fluid transport is motivated by pump 4720, which is coupled to double-T 4710 and to port 4730 (serving as an inlet in this embodiment to a heat exchanging chamber). Another port 4730 serves as an outlet from the heat exchanging chamber and is coupled to an outlet 4640 (not shown). Likewise, an inlet 4630 brings fluid in from the external loop of the system and to the double-T 4710.

FIG. 47C illustrates the cooling device of FIG. 47A in a cutaway perspective view. FIG. 47D illustrates the cooling device of FIG. 47A in a perspective view. Here, the relationship of the various components is somewhat more clear.

FIG. 47E illustrates an embodiment of a cooling device such as the cooling device of FIG. 47A in a perspective view. FIG. 47F illustrates the cooling device of FIG. 47E in a perspective view with hose connections illustrated. Cooling system 4750 uses essentially the same components as cooling systems 4700 and 4600. However, a smaller fluid reservoir 4750 is shown. Additionally, the hose connections further illustrate the fluid flow previously described with respect to cooling system 4700.

FIG. 48 illustrates another embodiment of a cooling device such as the cooling devices of FIG. 46A or FIG. 46F. Cooling system 4800 is schematically represented to provide a general understanding of the cooling systems of other embodiments. Cooling device 4600 is used, with an internal pump 4840, heat exchanger 4820 and reservoir 4810 coupled together as part of an open loop. This open loop is closed through connections (couplings) to a personal heat exchange garment, such as the shirts discussed previously.

FIG. 49 illustrates yet another embodiment of a cooling device such as the cooling devices of FIG. 46A or FIG. 46F. In particular, device 4990 may be implemented as any of devices 4600, 4700 or 4750, among other devices. System 4900 includes device 4990 and a personal garment 4960. Device 4990 includes a panel fitting (inlet) 4970, coupled to a double-T 4920. Double-T 4920 is coupled to a reservoir 4910 allowing for air purge and fluid fill/replenishment, and is also coupled to a pump 4930. Pump 4930 is further coupled to a heat exchanger 4940, which in turn is coupled to a panel fitting (outlet) 4950. Fitting 4950 and 4970 are coupled to personal garment 4960, completing the cooling loop.

In an embodiment, a system has been implemented and tested based on components and features as described above. This system provide an efficient ice-based driver cooling system, and may be used for other applications as well. The system delivers two or more hours of essentially constant driver cooling, eliminating a need to conserve ice in hot conditions. The dual-chambered design separates ice from driver cooling fluid. This allows use of other cooling media and of other heat transport media (e.g. glycol, saltwater, etc.) An external fluid reservoir may also be included in the system. A temperature control can be included with a controller which senses temperature and adjusts operation of the pump.

Other features include the integrated vertical baffles (dividers) which reduce sloshing of liquid in the heat exchange chamber. In one embodiment, the enclosure and lid are roto-molded polyethylene with an expanding plastic interior which insulates the heat exchange and reservoir chambers from external conditions. Air tight seals are provided as a result of precision molded parts in some embodiments, although gaskets can also be used. Rubber T-handles can be used to lock the lid in place in some embodiments. This insulation and highly specific design may increase and maximize ice life. Additionally, a high pressure pump may be used to enhance flow in high temperature conditions.

In one embodiment, the outer dimensions of the cooling device are 14.5″×11″×11.5″ with an empty weight of 16 lbs (7.3 kg). This provides for an ice capacity of 9 lbs (4.0 kg) and a reservoir capacity of 22 fluid oz (650 ml). The system in such an embodiment has been operated with a 1A power draw at a typical 13.8 VDC supply.

Note that aside from heat exchangers and cooling technologies described above, systems may also be implemented through use of Stirling engines as heat exchangers.

The entire system as described can be implemented in various different embodiments. An embodiment has been tested under a variety of conditions. It has performed well in keeping a driver cool in an automobile race under hot conditions. Likewise, it has performed well in keeping a driver warm in an automobile race under cold conditions. Another embodiment of the system designed for cooling has likewise been tested in a variety of conditions and has performed well.

One skilled in the art will appreciate that although specific examples and embodiments of the system and methods have been described for purposes of illustration, various modifications can be made without deviating from the present invention. For example, embodiments of the present invention may be applied to many different types of applications, such as vehicles, personal use, stationary use, temporary or permanent installations, or other environments. Moreover, features of one embodiment may be incorporated into other embodiments, even where those features are not described together in a single embodiment within the present document. 

1-30. (canceled)
 31. A system, comprising: A cooling device including a heat exchange chamber, a fluid reservoir and an equipment chamber, Wherein the heat exchange chamber includes a heat exchanger in fluid communication with the equipment chamber, Wherein the fluid reservoir is further in fluid communication with the equipment chamber, Wherein the equipment chamber includes a pump in fluid communication with the heat exchange chamber and the fluid reservoir, Wherein the pump is further in fluid communication with an inlet port and an outlet port of the cooling device; And A personal fabric component, the personal fabric component including fluid passages, the fluid passages in fluid communication with the inlet port and the outlet port of the cooling device.
 32. The system of claim 31, further comprising: A controller coupled to the pump.
 33. The system of claim 32, wherein: the personal fabric component is a personal garment, including: An inner layer formed from a wicking material, An internal bladder having a first outer layer and a second outer layer sealed along a perimeter of the internal bladder, the internal bladder further having a middle layer interposed between the outer layer and the inner layer and having voids therein defining a space in which fluid can circulate within the internal bladder, the internal bladder further having an inflow and an outflow tube interposed between the first outer layer and the second outer layer at the perimeter of the internal bladder, and An outer layer formed from a wicking material, the outer layer connected to the internal layer, the outer layer and the inner layer defining a pocket in which the internal bladder is enclosed, the pocket having an external opening aligned with the inflow tube and the outflow tube of the bladder.
 34. The system of claim 33, wherein: The heat exchange chamber is filled with ice.
 35. The system of claim 34, wherein: The fluid reservoir is filled with water.
 36. A system, comprising: A cooling device including a heat exchange chamber, an inlet and an outlet, Wherein the heat exchange chamber includes a heat exchanger in fluid communication with the inlet and the outlet, Wherein the heat exchanger is a bundle of metal tubes, Wherein the metal tubes of the heat exchanger are mounted to a metal plate of the inlet in an airtight manner, Wherein the metal tubes of the heat exchanger are mounted to a metal plate of the outlet in an airtight manner; A blower in fluid communication with the outlet of the cooling device and in fluid communication with a helmet; And An air intake port in fluid communication with the inlet of the cooling device.
 37. The system of claim 36, wherein: The blower further includes a filter interposed between the outlet of the cooling device and the helmet. 38-45. (canceled)
 46. A system, comprising: a cooling device for mounting in an automobile including a heat exchange chamber, a fluid reservoir and an equipment chamber, Wherein the heat exchange chamber includes a heat exchanger in fluid communication with the equipment chamber, wherein the fluid reservoir is further in fluid communication with the equipment chamber, wherein the equipment chamber includes a pump in fluid communication with the heat exchange chamber and the fluid reservoir, wherein the pump is further in fluid communication with an inlet port and an outlet port of the cooling device; a personal garment, the personal garment including fluid passages, the fluid passages in fluid communication with the inlet port and the outlet port of the cooling device, the personal garment including an inner layer formed from a wicking material, a first internal bladder having a first outer layer and a second outer layer sealed along a perimeter of the first internal bladder, the first internal bladder further having a middle layer interposed between the outer layer and the inner layer and having voids therein defining a space in which fluid can circulate within the first internal bladder, the first internal bladder further having an inflow and an outflow tube interposed between the first outer layer and the second outer layer at the perimeter of the first internal bladder, a second internal bladder having a first outer layer and a second outer layer sealed along a perimeter of the second internal bladder, the second internal bladder further having a middle layer interposed between the outer layer and the inner layer and having voids therein defining a space in which fluid can circulate within the second internal bladder, the second internal bladder further having an inflow and an outflow tube interposed between the first outer layer and the second outer layer at the perimeter of the second internal bladder, and an outer layer formed from a wicking material, the outer layer connected to the internal layer, the outer layer and the inner layer defining a first pocket in which the first internal bladder is enclosed, the first pocket having an external opening aligned with the inflow tube and the outflow tube of the first internal bladder, the outer layer and the inner layer defining a second pocket in which the second internal bladder is enclosed, the second pocket having an external opening aligned with the inflow tube and the outflow tube of the second internal bladder; and a controller coupled to the pump.
 47. The system of claim 33, wherein: the heat exchange chamber is filled with ice.
 48. The system of claim 33, wherein: the personal garment is a shirt.
 49. The system of claim 33, wherein: the personal garment is a suit. 